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

(Photo: Teslarati)

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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.

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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Tesla Robotaxi geofence expansion enters Plaid Mode and includes a surprise

Now, on August 26, the Robotaxi geofence has expanded once again, and is estimated to be about 130 square miles.

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Tesla has expanded its Robotaxi geofence in Austin for the third time since its launch in late June, and the company added a big surprise with this new service area.

After launching on June 22, Tesla’s driverless Robotaxi service has been expanded three times. Its initial launch was about 20 square miles in size. The first expansion occurred on July 14 and was roughly 42 miles large, more than double the initial geofence size.

The second expansion occurred on August 3 and brought the total service area to roughly 80 square miles.

Now, on August 26, the Robotaxi geofence has expanded once again, and is estimated to be about 170 square miles.

The expansion of the Robotaxi geofence seemed to show the company’s focus on getting the service to the areas East and West of downtown was an utmost priority.

We reported on the Bee Cave region of the Austin suburbs being a place where Robotaxi validation vehicles were spotted testing in recent days.

Bee Cave is included in the new geofence.

However, that is not the biggest addition to the geofence, and it’s not even close. Tesla added a major area to the new geofence, one that fans of the company will absolutely love: Tesla Gigafactory Texas.

The big question that remains is whether Tesla is expanding the size of its fleet of Robotaxi vehicles in Austin. There have been many questions about the expansions of the fleet and not necessarily the geofence, and while the latter is certainly considered progress, Tesla will need to enable more Robotaxi into the vehicle population to handle the additional rides.

Tesla has been planning to do so, but is still prioritizing safety and does not want to rush any part of the Robotaxi process.

Tesla is also looking to expand to new cities altogether. It is currently moving toward a Robotaxi launch in Florida, Arizona, and Nevada, and has also opened up job postings for Robotaxi operators in New York.

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Elon Musk reiterates his most optimistic prediction yet with “UHI” forecast

Despite his polarizing nature, Elon Musk is, at his core, an optimist.

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Joel Kowsky, Public domain, via Wikimedia Commons

Despite his polarizing nature, Elon Musk is, at his core, an optimist. If he were not one, he would never have founded Tesla or SpaceX, or pursued projects such as Neuralink or xAI.

Musk’s optimism was on full display on social media platform X recently, when he shared what could very well be his most optimistic prediction yet.

Robots and humans

The Tesla CEO recently responded to a post from David Scott Patterson, who estimated that all jobs will be replaced by AI and robots easily by 2030. In his post, Patterson noted that if robots are sold at the same rate as vehicles, it could result in an output of 320 million robots per year. 

Musk responded that eventually, intelligent humanoid robots will far exceed the population of humans, and “there will be many robots in industry for every human to provide products & services.” 

Musk is already taking steps to achieve such a future. Tesla’s Optimus humanoid robot is expected to see its first “legion” produced this 2025. During an All-Hands meeting earlier this year, Musk also hinted to Tesla employees that the company will try to produce about 50,000 Optimus robots next year. 

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Universal High Income (UHI)

Musk has shared similar sentiments in the past, so it was no surprise that some X users asked the CEO how humans could sustain their lives when robots replace working individuals. To this, Musk responded that a Universal High Income (UHI) would be implemented, which should provide people with the best medical care, food, and transport available.

“There will be universal high income (not merely basic income). Everyone will have the best medical care, food, home, transport and everything else. Sustainable abundance,” Musk wrote in his post

Musk’s comment about sustainable abundance seems to be a prevalent theme in his recent optimistic comments. During Tesla’s second quarter earnings call, for example, Musk hinted that his Master Plan Part Four will describe a path towards sustainable abundance in a post-autonomy world.

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Tesla FSD upcoming Australia release seemingly teased bv media

The videos showed FSD navigating lane changes, slowing for traffic, and handling curves without driver input.

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Credit: Tesla AI/X

New videos from Australia have fueled speculations that Tesla’s Full Self-Driving (FSD) will be rolling out in the country soon. 

The videos, which were shared widely on social media, showed Teslas navigating lane changes, slowing for traffic, and handling curves without driver input, but still with active supervision.

New FSD footage

One video, posted by lifestyle outlet Man of Many and narrated by journalist Ben McKimm, highlighted how quickly the system responded to real-world conditions. McKimm seemed quite impressed with FSD’s performance, stating that the vehicle performs maneuvers much like a human driver. 

Another video, which featured reporter Danielle Collin, featured a Tesla operating on public roads using its FSD (Supervised) system. Similar to McKimm, Collin seemed very impressed with the capabilities of FSD, as the vehicle was reacting to things like stop signs on its own. 

No regulatory barriers

This isn’t the first time the software has been seen on Australian roads. Earlier this year, Tesla released a clip of a Model 3 driving through Melbourne’s central business district with no visible driver input. A second video later surfaced from Sydney, reinforcing expectations that Australia could be among the first right-hand-drive markets to receive access.

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According to Tesla’s Australian website, FSD (Supervised) uses 360-degree camera visibility to manage blind spots, execute lane changes, and maintain awareness of surrounding vehicles, cyclists, and motorcycles. While Tesla notes that constant human oversight is still required for now, FSD is designed to handle city intersections, multi-lane highways, and traffic signals.

In an earlier statement to news.com.au, Tesla country director Thom Drew previously confirmed there were “no blockers in Australia” for a supervised release of FSD, similar to North America. “It’s something our business is working on releasing,” Drew said, though he did not provide a timeline.

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