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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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6 years ago

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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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Tesla’s new Model S and X spotted, but they leave a lot to be desired

The Model S and Model X testing mules spotted by The Kilowatts have few minor visual changes.

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3 hours ago

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May 23, 2025

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Credit: Tesla

Tesla has been hinting for a few months now that the flagship Model S and Model X would be getting some attention in 2025 as the vehicles continue to be sold in extremely low volumes.

Both models seem to be under the knife, especially as their newest versions were spotted in California earlier this week.

However, images of the vehicles seem to show that Tesla is not planning a major overhaul, which begs the question: why even do it in the first place?

Tesla makes a decision on the future of its flagship Model S and Model X

The Model S and Model X are grouped with the Cybertruck in Tesla’s quarterly delivery releases, and Q1 saw just 12,881 units of the three cars delivered. The Cybertruck likely made up the majority of this number, as some outlets reported around 6,400 deliveries of the all-electric pickup in Q1.

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This is unconfirmed.

The Model S and Model X have stuck around for “sentimental reasons,” according to CEO Elon Musk, who said back in 2021:

“I mean, they’re very expensive, made in low volume. To be totally frank, we’re continuing to make them more for sentimental reasons than anything else. They’re really of minor importance to the future.”

However, the cars seem to be in need of a serious refresh. As Tesla changed up the exterior aesthetic on both the Model 3 and Model Y, recent images captured of the Model X by The Kilowatts seem to show this is not the strategy with the Model X or Model S:

As we can see, the overall aesthetic of the X, if this is what Tesla plans to release, has literally no changes from a purely visual standpoint. There is the addition of the front bumper camera, which was first implemented on the Cybercab unveiled in October 2024, and then on the new Model Y this year.

There are some new 20″ wheels, and the interior has been fitted with ambient lighting.

The Model S looked to be relatively the same, other than these few hardware changes, including a rear diffuser on this Plaid that was spotted:

While these changes are welcome and should be beneficial, they don’t seem like they will encourage major sales growth, which might be something Tesla is okay with.

Admitting the two cars are low volume and not contributors to the company’s long-term goals, Musk is likely willing to just upgrade things to make these more compatible and better functioning with the Full Self-Driving suite.

Earlier this year, VP of Vehicle Engineering Lars Moravy said the S and X were not going anywhere and would get “some love” before the end of 2025:

“Just give it a minute. We’ll get there. The upgrade a couple of years ago was bigger than most people thought in terms of architecture and structure of the car got a lot better, too. But, we’ll give it some love later this year and make sure it gets a little bit…you know, with the stuff we’ve been putting in 3 and Y. Obviously, with 3 and Y, the higher volume stuff, you’ve gotta focus there.”

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It seems these strategies have held true — the S and X appear to be getting what the 3 and Y got with the ambient lighting and front bumper camera (at least on the Model Y).

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Tesla set for ‘golden age of autonomous’ as Robotaxi nears, ‘dark chapter’ ends: Wedbush

Tesla is set to win big from the launch of the Robotaxi platform, Wedbush’s Dan Ives said.

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4 hours ago

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May 23, 2025

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Tesla (NASDAQ: TSLA) is set to kick off its own “golden age of autonomous growth” as its Robotaxi platform nears launch and a “dark chapter” for the company has evidently come to a close, according to Wedbush analyst Dan Ives.

Ives has jostled his price target on Tesla shares a few times already this year, usually switching things up as the market sways and the company’s near-term outlook changes. His price target on Tesla has gone from $550 to $315 to $350 back to $500 this year, with the newest adjustment coming from a note released early on Friday.

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As CEO Elon Musk has essentially started to dwindle down his commitment to the Department of Government Efficiency (DOGE) altogether, Ives believes that Tesla’s “dark chapter” has come to a close:

“First lets address the elephant in the room…2025 started off as a dark chapter for Musk and Tesla as Elon’s role in the Trump Administration and DOGE created a life of its own which created brand damage and a black cloud over the story….but importantly those days are in the rear-view mirror as we are now seeing a recommitted Musk leading Tesla as CEO into this autonomous and robotics future ahead with his days in the White House now essentially over.”

Ives believes Tesla’s launch of Robotaxi should be the company’s way to unlock at least $1 trillion in value alone, especially as the Trump White House will fast-track the key initiatives the automaker needs to get things moving in the right direction:

“The $1 trillion of AI valuation will start to get unlocked in the Tesla story and we believe the march to a $2 trillion valuation for TSLA over the next 12 to 18 months has now begun in our view with FSD and autonomous penetration of Tesla’s installed base and the acceleration of Cybercab in the US representing the golden goose.”

There are some concerns moving forward, but none of which relate to the AI/autonomous play that Ives primarily focuses on within the Friday note. Instead, they are related to demand in both Europe and Asia, as Ives said, “there is still wood to chop to turn around Model Y growth” in both of those markets.

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Nevertheless, the big focus for Ives is evidently the launch of Robotaxi and the potential of the entire autonomous division that Tesla plans to offer as a ride-sharing service in the coming months. Ives also believes a 50 percent or more penetration of Full Self-Driving could totally transform the financial model and margins of Tesla moving ahead.

Aware of the setbacks Tesla could encounter, Ives still believes that Tesla will establish itself as “the true autonomous winner over” and that investors will recognize the AI vision the company has been so bullish on.

Ives pushed his price target to $500. Tesla shares are down just under 1% at the time of publication. They are trading at $337.88 at 11:45 on the East Coast.

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SpaceX Starship gets FAA nod for ninth test flight

The FAA has given the green light for Starship’s ninth test flight.

Published

23 hours ago

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May 22, 2025

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(Credit: SpaceX)

SpaceX has received FAA approval for the ninth test flight of the Starship rocket. The approval was delayed due to the federal agency finishing its comprehensive safety review of the eighth flight earlier this year.

The FAA said in a statement that it has determined that SpaceX has “satisfactorily addressed the causes of the mishap, and therefore, the Starship vehicle can return to flight.”

The eighth test flight occurred back on March 6. SpaceX completed a successful liftoff of Starship and the Super Heavy Booster, before the two entered stage separation a few minutes after launch.

Starship Flight 8: SpaceX nails Super Heavy booster catch but loses upper stage

The booster returned and was caught by the chopsticks on the launch pad, completing the second successful booster catch in the program’s history. However, SpaceX lost contact with Starship in the upper atmosphere.

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The ship broke up and reentered the atmosphere over Florida and the Bahamas.

The debris situation caused the FAA to initiate a mishap investigation:

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The FAA said it will verify that SpaceX implements all the corrective actions on Flight 9 that it discovered during the mishap investigation.

There is no current confirmed launch window, but the earliest it could take off from Starbase is Tuesday, May 27, at 6:30 p.m. local time.

To prevent any injuries and potentially limit any damage, the FAA has stayed in contact with various countries that could be impacted if another loss of vehicle occurs:

“The FAA is in close contact and collaboration with the United Kingdom, Turks & Caicos Islands, Bahamas, Mexico, and Cuba as the agency continues to monitor SpaceX’s compliance with all public safety and other regulatory requirements.”

The agency has also stated that the Aircraft Hazard Area (AHA) is approximately 1,600 nautical miles and extends eastward from the Starbase, Texas, launch site through the Straits of Florida, including the Bahamas and Turks & Caicos.

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For flight 8, the AHA was just 885 nautical miles.

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