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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 provides vehicles for German firefighters’ EV training program

The sessions were aimed at improving emergency services for accidents involving electric vehicles.

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Credit: Tesla Manufacturing/X

Firefighters from across Germany recently gathered at Tesla Gigafactory Berlin-Brandenburg to practice emergency procedures on electric vehicles. The first training session last weekend focused on dismantling Tesla vehicles using spreaders, shears, and saws, giving responders hands-on experience with modern EV construction and safety features. 

The sessions were aimed at improving emergency services for accidents involving electric vehicles, which, while less likely to catch fire than conventional cars, require special handling.

Challenges for first responders

During the exercises, firefighters discovered that Tesla vehicles’ sturdy, unified body panels, which are among the reasons why they are among the safest cars on the road, made cutting doors and roofs more difficult than in older vehicles, as noted in an rbb24 report.

“It was a real eye-opener,” firefighter Martin Haschick said, adding that his first attempt showed him “how not to do it, because we are also trained on older vehicles, and that took longer than I expected.” Tesla trainers demonstrated proper techniques to safely dismantle vehicles, emphasizing differences between older combustion-engine cars and today’s EVs.

Patrick Fath, head of the Tesla plant fire brigade, explained that hands-on experience with current EVs is critical, as scrap cars typically used in training do not reflect modern material strengths or technological design.

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“They naturally have a completely different level of technology and different material strengths. But what can happen to us in everyday life – on the highway, on the roads, involves modern vehicles,” Fath stated.

Future training programs

Tesla plans to continue offering training for regional fire departments and state fire service schools, with the Brandenburg Ministry of the Interior observing the initial sessions to provide feedback. Exercises currently avoid live fires or fluid leaks due to the factory’s location in a drinking water protection zone. Tesla covers the costs of these programs, aiming to enhance first responders’ knowledge of modern EV safety and accident procedures.

In a comment, Fath highlighted that electric vehicle fires should not be too much of a problem, considering that the vehicles don’t catch fire as often as their combustion-powered counterparts. “Studies and experience from recent years have already shown that electric vehicles catch fire far less often than conventional vehicles. We have far fewer flammable materials, no gasoline or diesel tank, and therefore fewer ignition sources,” Fath stated.

Authorities have announced similar conclusions. The German Insurance Association (GDV) has confirmed that EVs catch fire significantly less often than combustion-powered cars, with statistics showing that around 14,200 vehicles caught fire in Germany in 2023. At the time, no higher fire risk was found in EVs. Data from the US National Transportation Safety Board (NTSB) from 2024 also showed that about 25 out of 100,000 EVs catch fire, which is notably fewer than the 1,530 out of 100,000 combustion-powered vehicles that catch fire.

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SpaceX’s next project will produce Starships at a level that sounds impossible

1,000 rockets per year is an insane number, especially considering Starship’s sheer size.

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Credit: SpaceX

Elon Musk has revealed bold plans for SpaceX’s newest Starbase facility in Texas, predicting it will become a birthplace for “so many spaceships.” The upcoming “Gigabay,” a massive $250 million production hub in Starbase, Texas, is designed to manufacture up to 1,000 Starship rockets per year.

That’s an insane number of rockets for a single facility, especially considering Starship’s sheer size. 

One of the world’s largest industrial structures

SpaceX’s Gigabay is expected to stand roughly 380 feet tall and enclose 46.5 million cubic feet of interior space, making it one of the largest industrial structures to date. The facility will feature 24 dedicated work cells for assembling and refurbishing Starship and Super Heavy vehicles, complete with heavy-duty cranes capable of lifting up to 400 U.S. tons, as noted in a Times of India report.

Construction crews have already placed four tower cranes on-site, with completion targeted for December 2026. Once operational, the Gigabay is expected to boost SpaceX’s launch cadence dramatically, as it would be able to build up to 1,000 reusable Starships per year, as noted in a report from the Dallas Express. Musk stated that the Gigabay will be “one of the biggest structures in the world” and hinted that it represents a major leap in Starbase’s evolution from test site to full-scale production hub.

A key step toward Mars and beyond

Starship is SpaceX’s heavy-lift rocket system, and it remains a key part of Elon Musk’s vision of a multiplanetary future. The vehicle can carry 100–150 tonnes to low Earth orbit and up to 250 tonnes in expendable mode. With several successful flights to date, including a perfect 11th test flight, the Starship program continues to refine its reusable launch system ahead of crewed lunar missions under NASA’s Artemis initiative.

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Starship is unlike any other spacecraft that has been produced in the past. As per Elon Musk, Starship is a “planet-colonizer” class rocket, as the magnitude of such a task “makes other space transport task trivial.” Considering Starship’s capabilities, it could indeed become the spacecraft that makes a Moon or Mars base feasible. 

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‘You chose ambition’: Tesla Chair hails shareholders for backing Elon Musk’s vision

Denholm stated that the vote highlighted TSLA investors’ continued confidence in both Musk’s leadership and Tesla’s vision for an autonomous, AI-driven future.

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(Credit: Tesla)

Tesla Chair Robyn Denholm has issued a letter to shareholders celebrating what she described as “overwhelming support” at this year’s Annual Meeting, framing the approval of Elon Musk’s trillion-dollar pay plan as a defining moment in Tesla’s mission. 

Denholm stated that the vote highlighted TSLA investors’ continued confidence in both Musk’s leadership and Tesla’s vision for an autonomous, AI-driven future.

Denholm hails shareholder confidence

In her letter, which was posted by the electric vehicle maker on X through Tesla’s official handle, Denholm thanked investors for backing Proposals One, Three, and Four, items she said reaffirm Tesla’s “Master Plan Part IV” and its broader mission to accelerate sustainable prosperity. She characterized the shareholder vote as “a vote of confidence in our visionary leader, Elon,” crediting Musk with transforming Tesla into one of the most valuable companies in history.

“In a year when many tried to sow doubt and negativity, you chose a better future,” Denholm wrote. “You chose ambition. You chose to see what is possible. You chose to back the people who have been in the room since the earliest days, fighting for the mission that first brought us all together—a better world for humanity,” she wrote in her letter. 

Her comments framed Musk’s pay package approval not only as a governance milestone but as a symbolic endorsement of Tesla’s long-term trajectory across autonomy, AI, and energy innovation.

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“A whole new book” of innovation

Denholm highlighted Tesla’s push toward autonomy as the company’s next major growth phase, citing the Robotaxi program and Optimus humanoid robot as examples of bringing artificial intelligence “into the physical world.” She described this period as potentially “the largest value-creation event in Tesla’s history, and quite possibly in the history of humanity.”

The letter reaffirmed the board’s commitment to direct engagement with shareholders through Tesla’s online platform and live events. Denholm emphasized that feedback from investors “informs our strategy and strengthens us” as Tesla prepares for new technology rollouts and expanded AI capabilities.

“You, our shareholders, have given us the mandate and the runway to execute. We are humbled, and rest assured that we do not take that responsibility lightly… Thank you for believing in Tesla. Thank you for standing with us. We look forward to years of bold leadership and pioneering innovation, fueled by our commitment to creating a better future for all,” she wrote.

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