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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 might be doing away with a long-included feature with its vehicles

It appears Tesla is mulling the possibility of not including key cards with its vehicles any longer.

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Credit: Tesla

Tesla might be doing away with a long-included feature with its vehicles, as it could be looking to phase out something that very few owners utilize.

Tesla Key Cards are included when you purchase your vehicle, and they assist in the initial setup process. However, after that, they are not super useful or relevant to the owner, as many rely on their Phone Key through the Tesla App to access their cars.

As such, it appears Tesla is mulling the possibility of not including key cards with its vehicles any longer. According to some language that has been removed from vehicle Owner’s Manuals that talks about the inclusion of key cards with the car upon delivery:

“Tesla provides you with two Model 3/Y key cards, designed to fit in your wallet.”

That sentence was removed from Owner’s Manuals, according to Not a Tesla App, which first spotted the change.

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Interestingly, the timing of the phrase being removed from Owner’s Manuals comes just after Tesla launched its “affordable” Standard Models, and could be a small money-saving measure for the company.

Key Cards have been utilized by Tesla for its cars since 2017, as they became an included accessory with the vehicle. They still have their place and are useful for other applications, such as Valet service and even to be used by car owners if their phone is dead or if someone else needs to get into the car.

They can also be purchased in the Tesla Shop for $40.

It seems as if Tesla is planning to have owners be completely reliant on the Phone Key, which is more useful and convenient than carrying around the Key Cards.

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Although it is minor, it is yet another strategy Tesla is using to trim any sort of costs that can be eliminated and could save money in the long run.

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Elon Musk confirms Tesla FSD V14.2 will see widespread rollout

Musk shared the news in a post on social media platform X.

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Credit: Whole Mars Catalog/X

Elon Musk has confirmed that Tesla will be implementing a wide rollout of Full Self-Driving (FSD) V14 with the system’s V14.2 update. Musk shared the news in a post on social media platform X. 

FSD V14.1.2 earns strong praise from testers

Musk’s comment came as a response to Tesla owner and longtime FSD tester AI DRIVR, who noted that it might be time to release Full Self-Driving to the fleet because V14.1.2 has already become very refined.

“95% of the indecisive lane changes and braking have been fixed in FSD 14.1.2. I haven’t touched my steering wheel in two days. I think it’s time, Tesla AI,” the longtime FSD tester wrote

AI DRIVR’s comment received quite a bit of support from fellow Tesla drivers, some of whom noted that the improvements that were implemented in V14.1.2 are substantial. Others also agreed that it’s time for FSD to see a wide release.

In his reply to the FSD tester, CEO Elon Musk noted that FSD V14’s wide release would happen with V14.2. “14.2 for widespread use,” Musk wrote in his reply

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Mad Max mode makes headlines

One of the key features that was introduced with FSD’s current iteration is Mad Max mode, which allows for higher speeds and more frequent lane changes than the previous “Hurry” mode. Videos and social media posts from FSD testers have shown the system deftly handling complex traffic, merging seamlessly, and maintaining an assertive but safe driving behavior with Mad Max mode engaged.

Tesla AI head Ashok Elluswamy recently noted in a post on X that Mad Max mode was built to handle congested daytime traffic, making it extremely useful for drivers who tend to find themselves in heavy roads during their daily commutes. With Musk now hinting that FSD V14.2 will go on wide release, it might only be a matter of time before the larger Tesla fleet gets to experience the notable improvements of FSD’s V14 update.

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Multiple Tesla Cybercab units spotted at Giga Texas crash test facility

The vehicles were covered, but one could easily recognize the Cybercab’s sleek lines and compact size.

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Credit: @JoeTegtmeyer/X

It appears that Tesla is ramping up its activities surrounding the development and likely initial production of the Cybercab at Giga Texas. This was, at least, hinted at in a recent drone flyover of the massive electric vehicle production facility in Austin. 

Cybercab sightings fuel speculations

As observed by longtime Giga Texas drone operator Joe Tegtmeyer, Tesla had several covered Cybercab units outside the facility’s crash testing facility at the time of his recent flyover. The vehicles were covered, but one could easily recognize the Cybercab’s sleek lines and compact size. Tegtmeyer also observed during his flyover that production of the Model Y Standard seems to be hitting its pace.

The drone operator noted that the seven covered Cybercabs might be older prototypes being decommissioned or new units awaiting crash tests. Either scenario points to a ramp-up in Cybercab activity at Giga Texas, however. “In either case, this is another datapoint indicating production is getting closer to happening,” Tegtmeyer wrote on X, highlighting that the autonomous two-seaters were quite exciting to see.

Cybercab production targets

This latest sighting follows reports of renewed Cybercab appearances at both the Fremont Factory and Giga Texas. A test unit was recently spotted driving on Giga Texas’ South River Road. Another Cybercab, seen at Tesla’s Fremont Factory, appeared to be manually driven, suggesting that the vehicle’s current prototypes may still be produced with temporary steering controls.

The Tesla Cybercab is designed to be the company’s highest-volume vehicle, with CEO Elon Musk estimating that the autonomous two-seater should see an annual production rate of about 2 million units per year. To accomplish this, Tesla will be building the Cybercab using its “Unboxed” process, which should help the vehicle’s production line achieve outputs that are more akin to consumer electronics production lines.

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