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An inside look at Tesla’s P100D battery pack: more cells, 102 kWh capacity, backwards compatibility in mind

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New details of Tesla’s mysterious P100D battery pack, which Tesla CTO JB Straubel once described as having notable changes in battery module and pack technology, and a “complete redo on the cooling architecture”, have emerged thanks to Jason Hughes’s latest project.

Hughes posted photos of a dismantled 100 kWh battery pack, which he obtained through the purchase of a salvaged Tesla P100D, that reveal an increase in the number of 18650 lithium-ion cells being packed within each battery module. Hughes also discovered a surprising increase in battery capacity beyond 100 kWh, and what appears to be a replaceable connector that allows Tesla to retrofit older vehicles with the newer battery pack.

More 18650 Battery Cells

As outlined in Hughes’s blog post, Tesla was able to fit more of its cylindrical 18650 lithium-ion battery cells into each of the 16 modules making up the P100D battery pack. It’s worth noting that Tesla has maintained a relatively similar form factor on battery packs produced for Model S and Model X vehicles since their introduction. Regardless of the vehicle’s model version – be it a P85, a 60, 75D, or 90D – the uniform skateboard design of the battery pack allows for ease of production, as Tesla can manufacture a single-style pack that can be installed across its fleet of vehicles. Under that same notion, Tesla has also been able to create ‘unlockable features’ by software limiting vehicle range depending on the option purchased by the customer. In other words, Tesla installs the same battery pack into like-kind vehicles (e.g. Model S 60 uses the same pack as Model S 75).

Tesla P85 battery pack module vs. P100D module [Credit: Jason Hughes via @wk057]

Hughes’s dissection of the P100D battery shows that Tesla leveraged the same design concept by distributing a total of 8,256 battery cells across the 16 modules making up the battery pack, bringing total capacity up to the advertised 100 kWh number. However, and much to Hughes’s surprise – he had previously criticized Tesla for providing less battery capacity than what’s perceived by way of the vehicle’s nameplate – Tesla actually provided 102.4 kWh of capacity on the P100D pack, representing a 2.4% increase over what’s marketed.

Backwards Compatible Design

Tesla has also, seemingly, taken into account the ability to retrofit new battery packs onto older vehicles by using the same high and low-voltage connectors across packs. According to Hughes, “the pack itself has the same high-voltage connection, the same low voltages connectors, and the same cooling connector.” However, Hughes notes that there’s subtle changes on the P100D pack that would require a new part in order for it to be retrofittable onto non-P100D vehicles.

“The [P100D] pack has the newer ring around the high-voltage connector. So, it’s plug-and-play (for the most part, firmware and config changes needed) on the Model X and refreshed Model S, however it would require a different spacer ring on the high voltage connector. Tesla even has a part number for it, so it should be pretty simple to put into any Model S/X.” says Hughes.

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What about that new P100D battery cooling architecture?

Well. It’s not magic. Tesla did improve battery cooling in the new P100D 100 kWh battery pack. And Tesla did provide a redone architecture, but it isn’t one of mythical proportions.

Hughes reveals Tesla’s approach to improve battery pack cooling was to use shorter and thinner cooling loops per battery module, thereby improving the rate of heat dissipation. Unlike most other electric car makers who do not “prime” their vehicle’s batteries through the use of a thermal management system, Tesla pumps fluid through the battery module to regulate the temperature of its battery pack in order to bring them to optimal operating temperatures. By ensuring the lithium-ion cells operate within ideal temperatures, Tesla is able to provide the best performance possible, while ensuring cell longevity.

Tesla P100D battery module cooling loops [Credit: Jason Hughes]

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Tesla launches new color from Gigafactory Berlin

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Credit: Tesla

Tesla has launched a new color at Gigafactory Berlin in Germany, home of the company’s “world-class paint shop,” as Elon Musk once called it.

Bringing a new color to Tesla’s Model Y, there are now five available colors for those who will receive a vehicle from Gigafactory Berlin, with four of them being colors offered in other markets.

However, there is now one distinct color that is only available in Germany: Marine Blue.

Priced at €1,300, Marine Blue will cost the same as both Diamond Black and Stealth Grey, while Quicksilver and Ultra Red are available for double the price.

It is the third shade of blue Tesla offers across its lineup, as Deep Metallic Blue and Glacier Blue are also offered, but in other markets.

Tesla has routinely flexed Giga Berlin for having the most advanced paint shop throughout its factories, and it has produced some interesting colors over the past few years, some of which were truly awesome.

Tesla Giga Berlin is getting a world-class paint shop, new color ‘layers’ to come

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In 2020, Musk said, “Giga Berlin will have the world’s most advanced paint shop, with more layers of stunning colors that subtly change with curvature.”

He also detailed the company’s plans to upgrade the Fremont and Shanghai paint shops. Gigafactory Texas was not yet unveiled. Tesla has worked to improve those facilities, especially in Fremont.

It was able to roll out the new Diamond Black color earlier this year.

However, Giga Berlin seems to remain the standard in terms of paint for Tesla. It routinely offers new colors.

For example, back in 2022, Tesla rolled out its familiar Quicksilver color for the Model Y, while also introducing Midnight Cherry Red, a color close to burgundy. However, the company chose to discontinue the color after determining internally that customers no longer wanted to buy it.

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Midnight Cherry Red was removed as an option earlier this year, likely to make way for the development of the new Marine Blue.

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Tesla Autopilot visualization gets big upgrade with tons of new additions

The AP visualization shows up on the center touchscreen and illustrates the surroundings of the cars. It has gotten better in recent years, as it is able to outline types of vehicles, pedestrians, animals, and more.

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Credit: @greentheonly | X

Tesla’s Autopilot visualization just got a big upgrade as the company added tons of new additions to what it will be able to render in terms of a vehicle’s surroundings.

The AP visualization shows up on the center touchscreen and illustrates the surroundings of the cars. It has gotten better in recent years, as it is able to outline types of vehicles, pedestrians, animals, and more.

Tesla just fixed a four-year-old bug with Full Self-Driving visualization

However, it still does not have every single application, and acquiring them will take some time. If an object or vehicle is visible to the vehicle but an accurate render is not available, the car will instead pick whatever is closest.

For example, I passed an Amish family yesterday in Lancaster, PA, and instead of illustrating the horse and carriage, it simply showed a small box truck.

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In an effort to make the Autopilot and Full Self-Driving suites more robust and accurate, Tesla has added a substantial amount of vehicle renders, which will become available in the coming weeks.

The visualizations were found by Tesla hacker @greentheonly, who posted them on X.

The new visualization renders are:

  • Ambulance
  • Firetruck
  • Garbage Truck
  • Schoolbus
  • European Semi Truck
  • Golf Cart
  • Person on a Scooter
  • Person on a Skateboard
  • Stroller
  • Street Sweeper
  • Three-Wheeler
  • Trailer
  • Train
  • Tram
  • Person in a Wheelchair

Here is an image with all of the Autopilot visualization renders:

Credit: Green

The visualization is a crucial part of manual operation and can be considered a distinct advantage that Tesla has over other companies.

It continues to be an effort that Tesla invests heavily in, as it keeps refining the suite and making it more robust with additional visualizations and animations.

Recently, it was revealed that Tesla is planning to utilize Unreal Engine for driver visualization to create a realistic depiction of the vehicle’s environment. Tesla has not yet confirmed this, but coding found with the Model S and Model X showed it could be coming in the near future.

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Tesla dominates best-selling EVs in Q3, but there’s one disappointment

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(Credit: Tesla)

Tesla dominated the sales figures for electric vehicles in the third quarter in the United States, but there was one disappointment: the Cybertruck.

As a whole, the EV industry benefitted from the loss of the $7,500 EV tax credit in Q3, which was something many expected. As the credit expired, consumers rushed to showrooms to take the credit and remove $7,500 from the purchase price of their new vehicle.

Will Tesla thrive without the EV tax credit? Five reasons why they might

It was a very interesting time for many companies as they scrambled to figure out how to push as many vehicles out the door as they could in preparation for the tax credit’s removal. In typical fashion, Tesla was able to top every manufacturer and secure a dominating portion of the overall market in Q3.

However, some other OEMs pulled out some surprises, including Chevrolet, Honda, and Ford, which managed to get two vehicles in the top 10, as many as Tesla.

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Cox Automotive compiled the data in its Q3 Electric Vehicle Sales Report:

  1. Tesla Model Y – 114,897
  2. Tesla Model 3 – 53,857
  3. Chevrolet Equinox EV – 25,085
  4. Hyundai Ioniq 5 – 21,999
  5. Honda Prologue – 20,236
  6. Ford Mustang Mach-E – 20,177
  7. Volkswagen ID.4 – 12,470
  8. Audi Q6 e-tron – 10,299
  9. Ford F-150 Lightning – 10,005
  10. Rivian R1S – 8,184

10.5 percent of the automotive sales in the U.S. in Q3 were electric, a new record that surpasses that of Q3 2024, where the total share of sales for EVs was 8.6 percent.

Now, the disappointment that is evident from this list is the fact that there is no Tesla Cybertruck listed. That’s because it was the second-best-selling EV pickup on the market. The company sold 5,385 Cybertruck units in Q3.

The Cybertruck has been a vehicle that has confused many Tesla fans and owners, especially considering the company had such stratospheric expectations for the vehicle while it was in development. Reservation trackers had the truck sitting between one million and two million orders, but it has not lived up to that.

Pricing is the main issue with Cybertruck. Tesla introduced the pickup with Single, Dual, and Tri-motor configurations, priced at $39,990, $49,990, and $69,990. Those price points are simply a thing of the past.

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