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Exclusive: Porsche’s electric heart beats in the Taycan’s Zuffenhausen factory

(Photo: Teslarati)

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7 years ago

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Beside the red-bricked walls of Porsche’s headquarters at Zuffenhausen, an electric transformation is taking place. It is a transformation that echoes back to its earliest days, despite the company’s pedigree with the internal combustion engine. Tall, modern-looking buildings sit side-by-side with older factories and shops that have literally witnessed history. The faint sounds of heavy machinery are audible in the distance, a reminder that work in the historic site is ongoing.

“We’re building a factory within a factory within a city with residences close by, hardly any space, and this in high speed,” says Porsche representative of the project David Tryggvason, lightly pointing out that the timeframe of the project is very Porsche-like: Sporty.

Porsche is actively engaged in a massive construction project in its Stuttgart-Zuffenhausen site, roughly 120 miles from Frankfurt, with the company running full throttle as it prepares for the production of the Taycan. The result of these efforts could only be described as a rebirth of sorts, since the company that started with an electric car is now pushing itself to re-embrace all-electric vehicles, perhaps just as intended by its founder, Ferdinand Porsche, more than a hundred years ago.

Porsche’s Zuffenhausen site is located near residential and business areas. (Photo: Teslarati)

An electric transition

A lot is riding on the Porsche Taycan. During the company’s annual press conference, Porsche CEO Oliver Blume and Deputy Chairman of the Executive Board Lutz Meschke emphasized how all-electric vehicles like the Taycan and its lineup of hybrid cars are pertinent for the company’s future. In a statement, Meschke noted that by 2030, vehicles powered by an internal combustion engine would likely be the exception to the rule.

“One thing is clear: from 2030 onwards; there probably won’t be any vehicle model from Porsche without an electric variant. I actually presume that by 2025, we will have electrified significantly more than half of our entire model range. But the combustion engine will still be around in 2030. Our 911 will hopefully still be driving with them for a long time to come. Conventionally powered vehicles will at that point be the niche in our electric fleet,” he said.

Before it can produce a successful electric vehicle, Porsche needs to ensure that it has the facilities necessary to build a completely different type of car. The veteran automaker opted to construct several new facilities to accommodate the Taycan’s production, and it had to overcome numerous challenges to make the buildout possible. The Zuffenhausen site is a stone’s throw away from a residential neighborhood, and the site itself is split by a four-lane road. With space being scarce, Tryggvason notes that the company did the only thing it can do: it built up. Overall, building the Taycan is complex. Setting up the facility even more so. For the project manager, the challenges were worth it. “We believe in the product,” David said.

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One of Porsche’s buildings for vehicle production in Zuffenhausen. (Photo: Teslarati)

A high-stakes, collective effort

The company’s bet on the Taycan is evident in its investment for the vehicle and the actions of its own employees. Porsche is spending about 6 billion euros (around $6.81 billion) for the development of its electric mobility initiatives. Porsche Production 4.0, a campaign aimed at ushering in a new era of vehicle production, is also underway. Accelerating these developments is a deal that the carmaker struck with its employees, who agreed to forego a small part of their collective salary increase in exchange for their participation in the Taycan’s production and release.

David Tryggvason and Porsche Press Spokesman Jorg Walz later directed me to the roof of one of the new buildings, and I was able to get a pretty good view of the factory itself. They pointed out how the Taycan starts its life by having its electric motors, batteries, and axles assembled. The electric car’s body then gets put together, painted, and transported across a long conveyor system where it can go through final assembly and married to its electric drive unit.

A key to the successful production run of the Porsche Taycan is the company’s target of manufacturing the vehicle in a “smart, lean and green” manner. Examples of these include a flexi-line that uses automated guided vehicles for simpler assembly despite the expansive customization requests from Taycan buyers, optimizations in the use of resources and space, and an initiative to ensure that the entire production process of the all-electric car at Porsche’s Stuttgart-Zuffenhausen site is CO2-neutral. This is made possible through several programs such as the electrification of logistics vehicles, the use of waste heat in the paint shop, and a pilot trial that involves the adoption of nitrogen-absorbing facade surfaces, to name a few.

A render of the Taycan’s production line. (Credit: Porsche)

Race-bred batteries for a race-bred electric car

Not one to waste a rare opportunity to ask for details about the Taycan, I decided to ask a little about the electric car’s battery performance. Over the past year, several great electric vehicles were released by veteran carmakers such as Jaguar and Mercedes-Benz, but inasmuch as the machines themselves were impressive, their batteries left much to be desired. The I-PACE, for all its stunning interior and excellent design, is pretty much the electric equivalent of a gas guzzler. The Mercedes-Benz EQC seems to be the same.

Porsche uses pouch cells from LG Chem in the Taycan’s battery pack, which is expected to give the vehicle over 300 miles of range per charge under the NEDC standard. The company is aiming for ultra-fast 350 kW charging as well, thanks to its 800-volt technology, which was used first in Porsche’s LMP1 racecar 919 Hybrid. I asked how the Taycan’s battery holds up when charged continually with such a high rate of charge. Walz smiled and candidly stated “We’re very optimistic.”

After the annual press conference, I was able to sit in for an informal discussion of Porsche’s electrification with executive board member Detlev von Platen. The Porsche exec highlighted that the Taycan’s battery cells were closely developed by the company, thanks to its experience from its high-performance hybrid vehicles. Examples include the legendary Porsche 918 Spyder hypercar and the three-time Le Mans-winning Porsche 919 Hybrid racecar, both of which required some work in their batteries.

The Mission E sedan concept displayed in the Porsche Museum. (Photo: Teslarati)

“So we’re absolutely involved, deeply involved, in the development of the (Taycan’s battery) cells and the technology behind it. We haven’t started last year with the Taycan. We have worked since a long time already on battery technology from motorsport. Our prototypes like the 919 Hybrid was electrified. So I would say, in general terms, that we have started to work on battery technology at least ten years now,” Von Platen candidly said.

I was reminded of David Tryggvason’s overview of the Taycan’s components a couple of days before, when he remarked that some of the Porsche personnel who worked for the 918 Spyder hypercar also worked in the development of the Taycan. Upon hearing Von Platen’s description of Porsche’s work with batteries, I couldn’t help but agree with his point. Porsche has produced several iconic vehicles in the past, and the majority of them are powered by the internal combustion engine. Despite this, it is difficult to argue that the best cars the company has ever produced, such as the 919 Hybrid, are imbued with electric propulsion at their core. Beneath the roaring engines of the vehicles were electric motors and batteries that ultimately unlocked the cars’ real potential.

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Porsche’s first vehicle is an all-electric car. (Photo: Teslarati)

From the past to the future

An engineer at heart, Ferdinand Porsche started with an electric car at the end of the 19th century. He later dipped his feet in hybrid propulsion, before going ahead and gaining mastery of the internal combustion engine. From this perspective, the development of the Taycan feels like a homage to the company’s roots, and this is a big reason why Porsche is dead serious about the vehicle. In what appears to be a gesture to prove this, the Taycan is being built on the company’s most historic site, and it will be produced alongside the 911, a vehicle that can only be dubbed as the quintessential Porsche.

As I grabbed my travel gear and scurried to the remaining shuttle that was awaiting my presence, I looked back at Porsche’s headquarters one last time. There in the dark sky stood a marvel of orderliness in this ever-changing world. It was a moment that can only to be described as surreal, when the past breathes new life into the future. Seconds later, as I buckled myself down on the shuttle seat and gazed into a disappearing Zuffenhausen site, the sounds of whirring machinery and vehicles rolling off the factory floor can be heard in the distance. Beneath this orchestra of sounds were the rhythmic thumps of heavy equipment that continued to work tirelessly to build Taycan’s upcoming production facilities.

I couldn’t help but imagine that the sounds were representative of the electric heartbeat of a carmaker, coming to life once more.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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SpaceX opens up free Starlink service for those impacted by Hurricane Melissa

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2 hours ago

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October 28, 2025

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(Credit: Starlink | X)

SpaceX is opening up its internet service, Starlink, to those impacted by Hurricane Melissa, as it made landfall in Jamaica and the Bahamas as a Category 5 storm.

Hurricane Melissa is expected to reach wind speeds of over 165 MPH over the next few days as it extends out into the Atlantic Ocean by Thursday and Friday.

Citizens in Jamaica and the Bahamas have been preparing for the storm for the past week, getting necessary goods together and preparing for the massive storm to arrive. It finally did yesterday, and the first images and video of the storm are showing that it could destroy many parts of both countries.

Starlink is now being opened up for free until the end of November for those impacted by the storm in Jamaica and the Bahamas, SpaceX announced today:

It is a move similar to the one the company made last year as Hurricane Helene made its way through the United States, destroying homes and property across the East Coast. SpaceX offered free service for those impacted by the destruction caused by the storm.

The free Starlink service was available until the end of 2024.

Elon Musk’s companies have also made similar moves to help out those who are impacted by natural disasters. Tesla has offered Free Supercharging in the past, most notably during the California wildfires.

Tesla and SpaceX’s LA fire relief efforts: Cybertrucks, free Starlink and more

One major advantage of Starlink is that it is available for use in situations like this one, where power might be required to operate things like a modem and router.

Internet access is a crucial part of survival in these situations, especially as it can be the last leg some stand on to get in touch with emergency services or loved ones.

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Elon Musk

Tesla board chair reiterates widely unmentioned point of Musk comp plan

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3 hours ago

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October 28, 2025

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Credit: Tesla

Tesla Board Chair Robyn Denholm appeared on Bloomberg TV this morning to discuss the current status of CEO Elon Musk’s compensation plan, and used the opportunity to reiterate a widely unmentioned key point of the entire package.

Critics of the proposed pay package, which would pay Musk $1 trillion if he completes every tranche, routinely cite the sheer size of the payday.

Of course, many skeptics leave out the fact that he would only get that money if he were able to generate eight times the value the company currently has.

Tesla gains massive vote of confidence on compensation plan for Elon Musk

For Musk, it might have a little bit to do with money, but that is likely a very small percentage point of why the compensation package is being offered to him. He has reiterated that it is more about voting control and overall influence, especially as Tesla dives into robotics.

He said during the Q3 Earnings Call:

“My fundamental concern with regard to how much voting control I have at Tesla is if I go ahead and build this enormous robot army, can I just be ousted at some point in the future? That’s my biggest concern. That is really the only thing I’m trying to address with this. It’s called compensation, but it’s not like I’m going to go spend the money. It’s just, if we build this robot army, do I have at least a strong influence over that robot army, not current control, but a strong influence? That’s what it comes down to in a nutshell. I don’t feel comfortable wielding that robot army if I don’t have at least a strong influence.”

Tesla shares the idea that Musk is a crucial part of the company, and without him being awarded the voting control he feels he deserves, he could leave the company altogether.

The company is very obviously feeling the importance of the upcoming vote, as it has advertised and pushed heavily for the comp plan to be approved, mostly to retain Musk.

Tesla Board Chair Robyn Denholm said today to Bloomberg TV that it is crucial shareholders understand it is not about Musk’s potential wealth, but more about his influence on company decisions:

“So firstly, it is a performance package, so he gets nothing if he doesn’t perform against the pretty audacious milestones that are part of the performance criteria that’s been outlined by the board in the performance package. So, I think rather than compensation, it’s actually about the performance and the goals that we have for the company as we move forward. And so, for me, it really is about making sure that investors understand that they actually get paid if he hits the milestones before he will…Elon’s been very public, including on last week’s earnings call, about the fact that it’s around the voting influence that he could have in future shareholder meetings as opposed to the economic interests.”

Musk is not an incredibly flashy person. He does not have crazy cars or a massive house to go back to. He spends a lot of his time working and sometimes even sleeps at his office inside the factory.

He recently said he “only has what is needed” because “material possessions were making him weak.”

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The truth about Tesla ‘Mad Max’ mode from an actual user

Some people might see “Mad Max” as an extension of their daily driving.

For me, I did not see it that way. I saw it as a useful tool for certain situations, but it was certainly not something I could compare to my personal driving style.

But that does not mean that it’s wrong.

Published

4 hours ago

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October 28, 2025

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Credit: Teslarati

There have been many headlines about Tesla’s new “Mad Max” mode, but many of those writing about the “dangerous” and “controversial” mode have probably never used it.

As a writer, I write about topics I do not have firsthand experience with, but the job requires me to take a fair stance and report what is known. The problem is the nature of driving and driving modes, specifically, is subjective.

Some people might see “Mad Max” as an extension of their daily driving.

For me, I did not see it that way. I saw it as a useful tool for certain situations, but it was certainly not something I could compare to my personal driving style.

But that does not mean that it’s wrong.

NHTSA Probes Tesla Over “Mad Max”

Last week, the NHTSA launched a bit of a probe into Mad Max mode, requesting additional information on the Speed Profile and reiterating that the driver of the car is still required to be in ultimate control.

Tesla ‘Mad Max’ gets its first bit of regulatory attention

It’s important to keep the latter portion of that sentence in mind for the true thesis of this piece.

Now, it is no surprise to me that Mad Max garnered attention from regulatory agencies, as it is definitely a more spirited driving profile than the others.

Is Mad Max That Big of a Deal?

Regulatory agencies are responsible for keeping people safe, and it is important to note that their control is somewhat necessary. However, this type of drive mode is optional, requires the driver’s attention, and should be used responsibly for safe travel.

Playing Devil’s Advocate, how is Mad Max any different than the performance modes that some sports cars have? Because they require the driver to operate fully, and they are not semi-autonomous like Tesla can offer with Mad Max in Full Self-Driving (Supervised), are they safer?

The argument here really comes down to whether FSD is being used responsibly and correctly; any accelerated drive mode becomes more of a risk if the vehicle operator is not paying attention. This applies to any car company or drive mode they choose to use on their cars.

My Personal Experience with Mad Max

I have used Mad Max probably ten times since it rolled out to Early Access Program (EAP) members a few weeks ago.

I’ll admit: it did a lot of things I would never do driving a car manually. It passed people on the right. It was the fastest vehicle on the interstate, at least until I crossed into Maryland. Then, it seemed to be just another car on the road.

It drove quickly, and not so fast that I felt concerned for my safety, which I never feared for, but fast enough that, at certain points, I was concerned that a cop would pull me over. I never encountered that scenario, but I wouldn’t be surprised if it resulted in some tickets.

With that being said, I don’t particularly think I’d use Mad Max in more than a handful of applications: driving the Baltimore Beltway would be one instance, navigating traffic in Baltimore, Philadelphia, or Pittsburgh during heavy traffic, or cruising on I-95, where cars routinely are going 100 MPH, much faster than Mad Max would ever travel.

Is it too quick for me in residential settings? For me, yes. Is it faster than every human driving on those roads? Absolutely not. In my experience, it is quicker than some, slower than others, just like any other Speed Mode Tesla offers, even Sloth, which refuses to go over the posted speed limit.

I think it’s wrong to sit here and act as if Mad Max is some incredibly dangerous and life-threatening hazard. If a driver is uncomfortable with the maneuvers or speed, they do not have to use it. However, it is no different from how many other cars travel on the road; it is far from an anomaly.

Tesla FSD’s new Mad Max mode is getting rave reviews from users

With that being said, it will be interesting to see if the NHTSA does anything about Mad Max, whether it will require Tesla to “nerf” the Speed Profile, or remove it altogether. It’s also important to note that this is my personal experience with Mad Max, and what I’ve experienced might differ from others’.

I would love to hear your thoughts on how Mad Max has driven for you, or your impressions of it.

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