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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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Sweden blocks Tesla FSD-style testing in Stockholm

It looks like FSD testing in Sweden would have to wait some time.

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Credit: Tesla AI/X

Tesla is putting a lot of effort into getting its Full Self Driving (FSD) system approved in territories outside North America. But while China seems to have embraced FSD fully, other countries like Sweden do not seem to be receiving Tesla’s automated driving system very well.

This became quite evident in a document from Stockholm City, which has started making the rounds online.

FSD Testing Rejected

The document, which was initially shared by X user @KRoelandschap, indicated that the Swedish Traffic Department in Stockholm had rejected Tesla’s request to start FSD testing in the city’s streets. Tesla has been demonstrating FSD in several areas across Europe, so it is not surprising that the company is also attempting to test its automated driving system in Sweden.

Unfortunately for Tesla, Sweden might prove to be a tough nut to crack. As per the City of Stockholm: 

“The Traffic Office is currently working on updating its approach to automation. At the same time, the city and the office are under heavy pressure from other ongoing innovation tests. Our ambition is to actively participate in and learn from the continued development in the field of automation. 

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“Based on this, and in combination with the fact that the current test is the first of its kind, which entails certain risks for both infrastructure and third parties, and that it is planned to be carried out throughout the city, the City of Stockholm considers it is currently not possible to approve the implementation of the test.”

Tesla’s Other Swedish Troubles

Sweden’s FSD testing rejection is not the only roadblock facing Tesla in the country. Since October 2023, Swedish unions have been engaged in an active effort to disrupt Tesla’s operations. The unions’ efforts have been varied, with some resulting in Tesla having difficulty launching more Superchargers in Sweden. Despite this, Tesla has remained stubborn and has refused to bow to the unions’ demands.

Fortunately for Tesla, it seems like its numbers are still strong. Despite the company’s decline in several European countries, the new Model Y is starting to see strong sales figures in Sweden. In early May alone, the new Model Y became the country’s most popular electric vehicle—a notable accomplishment considering the unions’ active efforts to disrupt Tesla.

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Tesla firmware shows new Model Y seat configuration is coming

Tesla could be adding another seating configuration beside the seven-seater to the Model Y lineup later this year.

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Credit: Tesla

Tesla firmware has been a great place for some to reveal what the company has in the pipeline, and a new seating configuration for the best-selling Model Y looks to be on the way.

Last week, we reported that Tesla was already hinting toward a 7-seater configuration of the Model Y in a promotional email it sent to those on its contact list.

However, firmware revealed by Tesla hacker greentheonly is showing that a new seating configuration is on the way — a six-seater:

Green says the configuration would not be available in China-only, and will be potentially for sale in other markets as well.

The six-seat and seven-seat configurations of the Model Y were available in the Legacy version of the vehicle, but were met with mixed reviews, as many complained about the lack of legroom in the third row.

This was something that was a real concern for many of those owners who needed something larger than the traditional five-seat variant, but did not want to buy the much more pricey Model X.

We’ve covered the size of that third row on several occasions.

Some owners even took the idea of having a seven-seater into their own hands:

Tesla Model Y third row seat test explores options for a comfortable 7-seat setup

Tesla did not explicitly announce a six-seater configuration of the Model Y, but Lars Moravy, the company’s VP of Vehicle Engineering, said the seven-seater would come to production later in 2025.

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Tesla confirms massive hardware change for autonomy improvement

Tesla has confirmed that a recent change made to some of its recently refreshed vehicles is, in fact, a strategy it will use to improve its suite as it continues to work toward autonomy.

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Credit: Tesla

Tesla has confirmed that a recent change made to some of its recently refreshed vehicles is, in fact, a strategy it will use to improve its suite as it continues to work toward autonomy.

Tesla first introduced a front-facing camera on the front bumper with the Cybertruck.

Then, the Model Y “Juniper” received the hardware update. The Model S and Model X both received the front-facing camera with its latest update, which was officially revealed last week.

Tesla used new language with the release of the front-facing cameras on the Model S and Model X, confirming they will assist with several things, including “using Autopilot and Actually Smart Summon capabilities”:

“Enhanced visibility when parking or using Autopilot and Actually Smart Summon capabilities.”

This tiny feature on the new Tesla Model Y is perhaps its biggest addition

This is the first time Tesla has used this sort of language, as it was a completely different description with the launch of the new Model Y in January.

When Tesla launched this vehicle, it said the front bumper camera “provides a wider field of view for automatic assisted driving and advanced Smart Summon.”

Tesla switched from using cameras and sensors to only cameras with the launch of Tesla Vision several years ago. The company’s utilization of cameras comes from Tesla’s belief that Ultrasonic Sensors (USS) are not needed for self-driving efforts:

“Along with the removal of USS, we simultaneously launched our vision-based occupancy network – currently used in Full Self-Driving (FSD) (Supervised) – to replace the inputs generated by USS. With today’s software, this approach gives Autopilot high-definition spatial positioning, longer range visibility and the ability to identify and differentiate between objects. As with many Tesla features, our occupancy network will continue to improve rapidly over time.”

CEO Elon Musk has said that sensors were only a crutch and that self-driving would be solved through the use of cameras:

“When your vision works, it works better than the best human because it’s like having eight cameras, it’s like having eyes in the back of your head, beside your head, and has three eyes of different focal distances looking forward. This is — and processing it at a speed that is superhuman. There’s no question in my mind that with a pure vision solution, we can make a car that is dramatically safer than the average person.”

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