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Tesla’s Elon Musk details Model Y manufacturing improvements, insight on design

Tesla Model Y outside Fremont seat factory. | Image: Reddit u/backstreetatnight

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Tesla CEO Elon Musk recently revealed improvements the all-electric car maker has made to its production process for the Model Y crossover SUV. In an interview on Ride the Lightning podcast, hosted by Ryan McCaffrey, Musk discussed lessons learned from Tesla’s prior transition from the Model S to the Model X as applicable to the Model Y, as well as decisions made from the vehicle’s outgrowth of the Model 3. He additionally provided some insight on the design decisions behind the Model 3, which also carry over to the Model Y’s design.

Musk and McCaffrey’s discussion about the Model Y production process began with the question, “What are the biggest lessons learned from the Model 3 program that you’re applying to the Model Y?” However, Musk indicated that a more relative learning comparison came from Tesla’s design of the Model X and its departure from the Model S.

“The Model X ended up being a radical departure from the S…with the Model Y, we wanted to avoid the technology bandwagon we had with the X. It should have been easy going from S to X, but instead, it was hell because of so many new technologies…It would be too risky to the company to do that with the Y,” Musk explained.

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The Model Y crossover needed to address the flexibility expected of vehicles in its class such as cargo capacity, seating for 6 or 7 people, and more ride height than a sedan. Tesla addressed these features while also keeping in mind the effect on battery range a larger vehicle might have, according to Musk.

“We tried to make the car as similar to the [Model 3] as possible except in the case where a change was necessary to achieve SUV functionality…[all] while still having a low drag coefficient and not increasing the frontal area too much,” he detailed. Overall, Musk concluded that CdA (automobile drag coefficient) and mass of the Model Y only affect 8-10% of the battery range when compared to the Model 3.

The design of Tesla’s Model Y and lessons learned from Model 3 production also led to some manufacturing improvements for the electric crossover. Musk detailed how the Model Y underbody was switched to aluminum casting instead of stamped steel and aluminum pieces, which greatly simplifies the moving parts involved in making the vehicle.

This change effectively means that initially, using two castings to make the structure will take the process from 70 parts to 4 (castings plus joiners), and once the “big” casting machine comes into operation, the process will have brought the process from 70 parts to 1 (casting only). Using casting over stamping reduces the weight of the Model Y, improves MHB (heat produced), lowers cost due to the smaller number of parts necessary, and significantly drops capital expenditure on robots.

Tesla’s factory in Fremont is largely driven by a robotic manufacturing process. | Image: Tesla

As for the manufacturing location of the Model Y, Musk said the decision was not quite final, but the default place was Tesla’s factory in Fremont, California, with the runner-up being Gigafactory 1 in Sparks, Nevada. Producing the Model Y in Fremont would be the fastest way to bring the crossover SUV into production, according to Musk. “One choice isn’t natural over other,” he said. Freemont is producing the Model 3 and the two vehicles share 75% of their components, but Gigafactory 1’s location has a lower cost of living, meaning an overall better value for Tesla.

The similarities between the Model Y and Model 3 being what they are, Musk also discussed with McCaffrey some of the design decisions that initially went into creating the Model 3. In response to the question, “What’s the toughest design decision you had to make on Model 3?”, the CEO cited two primary factors that went into the midsize sedan’s creation: the touchscreen and the nose design.

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Reducing the number of screens from two in the Model S to one in the Model 3 came with some pushback, Musk explained. However, he felt that owners would prefer an open view of the road, and everything needed while driving could be fit onto one screen.

This background brought up community rumors about a heads-up display (HUD) being included in Tesla’s vehicles. On the subject, Musk set the record straight – there was never any plan to include a HUD, nor will one be added in the future. He simply doesn’t like them, and the move to self-driving makes them pointless. “We discussed it, but I’ve tried various heads up displays and found they were annoying,” he said. “We felt the car would increasingly go to self-driving…As things are approaching autonomy, why project things you don’t even care about on the screen?”

The nose of Tesla’s Model 3, which decidedly does not look like Lord Voldemort. | Image: Tesla

Something that customers do care about, though, is the look of their car. Musk detailed the difficulties in making an attractive design for the Model 3, which wasn’t easy thanks to the lack of a front grill on the vehicle. “You don’t want to have the nose to look like Voldemort…You’ve got to get some character or it does not look good.”

Also mentioned was the decision to reduce the width of the Model 3 to 185 cm over the 195 cm of the Model S to help sell more cars in Japan. The country’s parking machines only accept cars up to 195.4 cm wide, which leaves very little wiggle room in the manufacturing process to meet. The change to 185 cm meant that any Tesla Model 3 could fit in any parking garage in Japan.

The Model Y is set to begin production in 2020, and reservations are currently open on Tesla’s website.

Listen to McCaffrey’s full Ride the Lightning podcast interview here.

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Accidental computer geek, fascinated by most history and the multiplanetary future on its way. Quite keen on the democratization of space. | It's pronounced day-sha, but I answer to almost any variation thereof.

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Investor's Corner

Tesla tailwinds could drive momentum-filled finish to 2025: analyst

Tesla is heading toward some momentum to finish out the year, one Wall Street firm believes.

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Credit: @heydave7/X

Tesla has some tailwinds that could drive it toward a momentum-filled finish to the year, one Wall Street analyst is predicting.

The tailwinds are joined by some minor risks that have impacted the broader electric vehicle market, but overall, this firm believes Tesla has many catalysts moving forward.

Emmanuel Rosner of Wolfe Research believes that Tesla has plenty of things that could drive the stock upward as we approach the end of the year. With Q3 well underway, Tesla has about five months of catalysts to rely on to erase the roughly 18 percent drop in stock price it has so far this year.

At first glance, it is easy to see the things that would have investors bullish on Tesla for the rest of 2025 and even beyond. Initially, the Robotaxi launch and expansion, which spread to Northern California last night, provide potentially huge tailwinds for the company moving forward.

Tesla expands Robotaxi operation to California’s Bay Area

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Along with that, and slightly related, are the advancements in Full Self-Driving that the company has made over the past few months.

This includes the potential launch of the FSD suite in regions like Europe and Australia, where the company believes it will make some progress on regulatory approval in the coming months.

Finally, Wolfe says the company’s Optimus project, which is expected to enter scale production sometime next year, is the third catalyst for Tesla moving forward.

With these three projects in motion, Tesla truly can begin to work on rebounding from a rough 2025 on the market.

Rosner writes:

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“This name trades more around the narrative than the numbers. And net-net, we tactically see an improving narrative from here. Tesla has several catalysts coming up w/r/t FSD and Robotaxi, including an expansion of their AV service into several new U.S. markets (San Francisco, Nevada, Arizona, Florida, etc.). The company plans to unlock hands-free/eyes-off autonomy for FSD owners in select U.S. locations by YE25. Supervised FSD in China and Europe is expected to launch over the next ~12 months. And, Optimus is expected to enter scale production in 2026.”

Tesla is currently trading around $310 at around 3:20 p.m. on the East Coast.

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Two driverless Waymo cars collide at Phoenix Sky Harbor Airport

Two Waymo vehicles collided at Phoenix Sky Harbor Airport in Arizona

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waymo self-driving crash in phoenix
Credit: Reddit | u/HIGH_PRESSURE_TOILET

Two driverless Waymo cars collided at Phoenix Sky Harbor Airport on Wednesday, but details are incredibly slim as the accident has barely been mentioned on many social media platforms.

The video of the two Waymo vehicles was shared on Reddit’s r/SelfDrivingCars subreddit by u/HIGH_PRESSURE_TOILET (an interesting username), showing the two Jaguar I-PACE EVs at a standstill.

They were still making contact in the video, with one front driver-side quarter panel still in contact with the other’s front passenger door:

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There are relatively no details on the matter, but we reached out to Waymo earlier today, and an employee was able to share the following information.

Waymo told Teslarati that the accident occurred at a low speed, which is evident based on the lack of major damage done to either vehicle. Waymo did not reveal a specific speed at which the accident occurred, but they did mention it was a low speed.

The message Waymo’s vehicles showed after the accident in Phoenix. (Credit: Reddit | u/HIGH_PRESSURE_TOILET)

Additionally, there were no passengers inside either vehicle at the time of the crash. The cause of the accident is still unknown, but the company is currently investigating any potential causes and aims to have more answers in the coming days.

This is an expected growing pain of driverless vehicles, as autonomous rides are still in their very early phases. We have seen Waymo vehicles encounter a variety of challenges over the past several years, including getting stuck at construction zones in other cities.

Here’s one example of one nearly driving into a trench:

Waymo self driving car almost drives into a trench at construction site

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Waymo is in direct competition with Tesla Robotaxi, which is operating in both Austin, Texas, and the San Francisco Bay Area. Waymo operates in both of these areas.

As Waymo updates us with more details, we will share them here and update the article.

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Tesla tips off where it wants to expand Robotaxi next

Tesla looks to have its sights on several major cities in the United States to expand Robotaxi operation.

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Credit: @AdanGuajardo/X

Tesla has tipped off where it wants to expand its Robotaxi ride-hailing platform next, as it has launched rides in the San Francisco Bay Area on Thursday.

Austin, Texas, and the Bay Area of California are the two areas where Tesla is currently operating its ride-hailing service. In Austin, there is nobody in the driver’s seat, whereas in California, the rides will operate with someone in the driver’s seat.

This is a regulatory difference, but it is not all bad. California’s geofence for the ride-hailing service is nearly 70 miles long and spans from above San Francisco to the south, all the way down to San Jose.

However, this is not where Tesla is stopping. Expansion is going to occur when Tesla is ready to do so, but it is not being conservative with its expectations.

During last week’s Q2 2025 Earnings Call, Tesla CEO Elon Musk said he expects half of the U.S. population to have access to Robotaxi by the end of the year:

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“As we get the approvals and prove out safety, we will be launching the autonomous ride-hailing across most of the country. I think we will probably have autonomous ride-hailing in probably half the population of the US by the end of the year. That’s at least our goal, subject to regulatory approvals. I think we will technically be able to do it. Assuming we have regulatory approvals, it’s probably addressing half the population of the US by the end of the year. We are being very cautious. We do not want to take any chances, so we are going to go cautiously. But the service areas and the number of vehicles in operation will increase at a hyper-exponential rate.”

In order to do this, Tesla will need to expand to additional cities. A recent list of job postings captured by Tesla Yoda on X showed that the automaker is hiring in major metropolitan areas of the U.S. to reach more people.

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The cities listed in the job postings are:

  • Palo Alto, California
  • Brooklyn, New York
  • Houston, Texas
  • Dallas, Texas
  • Tempe, Arizona
  • Las Vegas, Nevada
  • Tampa, Florida
  • Orlando, Florida
  • Miami, Florida

Accessing markets like New York City, Dallas, Las Vegas, Miami, Tampa, and Orlando will enable Tesla to gain access to more customers. These are also major hotspots for tourism in the United States, where people might be able to get Tesla Robotaxi rides during trips or vacations.

These cities are unconfirmed to be in Tesla’s sites as it has not made any official statements about where it will expand in the future. However, these job postings are a good indication of where it could be looking in order to expand.

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