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Tesla firmware reveals ~110 kWh battery pack expected to shatter 400-mile barrier

Blue Tesla Model S with Plaid Powertrain returns to the Nurburgring. (Credit: Teslarati)

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Tesla is working on a new 110 kWh battery pack configuration that can stretch range well beyond 400 miles, according to a new discovery made in Tesla’s battery management system (BMS) firmware.

Jason Hughes, a notable Tesla owner and hacker who first uncovered the company’s plans for a “P100D” variant in 2016, found references to a larger battery pack capacity in the latest BMS firmware. “There is a packID that starts life set to ~109 kWh usable (400+ miles),” noted Hughes via Twitter, further suggesting that Tesla might be preparing for a battery pack as large as 115 kWh in capacity when factoring Tesla’s battery reserve.

Additionally, Hughes discovery points to a new battery pack configuration with 108 cells per group at ~450 volts per pack that could very well be a universal design to replace the aging Model S and Model X battery pack, while centralizing architecture for the Model 3 and upcoming Model Y.

Battery pack improvements don’t come as a surprise considering CEO Elon Musk disclosed during the Tesla Q4 2019 earnings call that the company is rapidly approaching a 400-mile range for the Model S. “It won’t be long before Model S has 400-mile range,” said Musk.

Just last week, Tesla Model S received a range boost from 370 miles to 390 miles of EPA-rated range, while the flagship Model X SUV saw an increase from 328 miles to 351 miles.

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With confirmation from Tesla CEO Elon Musk that the next-generation Model S and Model X will utilize a larger capacity battery to support its new Plaid Powertrain, the latest leak by Hughes can be seen as further validation that new battery advancements will be announced soon.

A future battery pack upgrade can only help Tesla break the 400-mile barrier and widen the range gap with any would-be competition. Tesla ups the ante and solidifies its position as the leader of the pack in the electric vehicle industry with its focus on new battery advancements – something the community expects Elon Musk to present in its upcoming “Battery Day”.

A curious soul who keeps wondering how Elon Musk, Tesla, electric cars, and clean energy technologies will shape the future, or do we really need to escape to Mars.

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Tesla Gigafactory Texas builds its half millionth vehicle

The milestone was shared via Twitter/X by the official @Gigafactories account.

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Credit: Tesla Manufacturing/X

Tesla’s Gigafactory Texas has officially rolled out its 500,000th vehicle, marking a significant achievement in the factory’s history and reinforcing its role as a central hub in Tesla’s vehicle manufacturing network. 

The milestone was shared via Twitter/X by the official @Gigafactories account. “Congratulations to the Giga Texas team for building 500k vehicles,” the company’s X post read.

As could be seen in Tesla Manufacturing’s post, the Gigafactory Texas team celebrated the milestone by posting for a photograph with the facility’s half millionth unit, a white Tesla Model Y. The team held balloons that spelled “500K” on its commemorative photo. 

Giga Texas, located near Austin, has ramped its operations since its launch, producing Tesla’s Cybertruck and Model Y. Crossing the half-million vehicle mark solidifies the facility’s importance to Tesla’s overall operations, especially considering the fact that the Model Y is the company’s best-selling vehicle.

While Giga Texas is just producing the Model Y and the Cybertruck for now, the facility is also poised to produce the Cybercab. The Cybercab is expected to be Tesla’s highest volume vehicle, with Elon Musk estimating that the company would be producing about 2 million units of the autonomous two-seater per year. 

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The Cybercab is unlike any vehicle that is currently produced today, and its production would be quite extraordinary. As per Elon Musk’s previous comments, the Cybercab’s manufacturing line would not look like an automotive production line at all. Instead, Musk noted that the Cybercab’s line in Gigafactory Texas would resemble a high-speed consumer electronics line instead.

“We do want to scale up production to new heights obviously with the Cybercab. Cybercab is not just revolutionary car design. It’s also a revolutionary manufacturing process. So I guess we probably don’t talk about that enough, but if you’ve seen the design of the Cybercab line, it doesn’t look like a normal car manufacturing line. It looks like a really high-speed consumer electronics line,” Musk previously stated.

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Tesla reportedly places large order for robot parts, hinting that Optimus V3 design is all but finalized

Tesla has reportedly placed a large order of linear actuators for humanoid robots from a Chinese supplier.

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Credit: Tesla

Tesla might have all but finalized the design for its Optimus V3 humanoid robot, at least if rumors from China prove accurate. As per recent reports, Tesla has reportedly placed a large order of linear actuators for humanoid robots from a Chinese supplier, with deliveries expected sometime in the first quarter of 2026.

The volume of orders suggested by the reports from China suggests that the components will not just be used for Optimus prototypes.

The rumor

As noted in a report from Sina News, media outlets across China have recently reported that Tesla has placed a $685 million (5 billion RMB) order for linear actuators from Sanhua Intelligent Controls. The components will reportedly be used for the production of Optimus, which will likely be mass-produced in its V3 iteration. The reports claimed that the delivery of the actuators will likely start sometime in the first quarter of 2026. 

Industry watchers have estimated that such a volume would be enough for about 180,000 Optimus robots. This suggests that while Tesla might not be able to start the initial production of its humanoid robots this year, the electric vehicle maker might be able to hit the ground running with its Optimus production next year. And as hinted at by Elon Musk’s comments on X, Tesla seems to be preparing to produce Optimus V3 en masse.

Company comments

The reports of Tesla’s alleged actuator orders have resulted in Sanhua Intelligent Controls’ stock rising. Interestingly enough, a Tesla China representative has stated that “no official information about this order that could be disseminated externally.” A representative from Sanhua, on the other hand, simply stated that the company’s robotics business is progressing smoothly, but they could not comment on market rumors. 

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While these reports are rumors for now, there are some optimistic hints that Tesla might have all but finalized the design for Optimus V3, and the company might be looking to start the robot’s production. For one, Sanhua is already a Tesla supplier, providing components for the company’s electric cars. A report from The Information also alleged that Tesla is no longer looking to produce 5,000 Optimus robots in 2025. This was reportedly due to challenges in the robot’s hands.

If Tesla is really starting to order large volumes of components for Optimus’ production, it would suggest that the company might have overcome the challenges it was facing with the humanoid robot earlier this year. It would then not be farfetched if Tesla were able to start the initial production of Optimus V3 next year.

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Tesla eyes two new states for Robotaxi

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Credit: @TerrapinTerpene/X

Tesla has officially shown that it is eyeing two new states for Robotaxi operation in the U.S., as it hopes to add the new areas to its ever-growing list of places where the suite is either active or in the testing phase.

Tesla first launched its Robotaxi suite in Austin, Texas, in late June. It expanded the suite to the San Francisco Bay Area just a month later. Since then, it has not launched any public rides in any other states, but it has gained several approvals for early testing.

Tesla officially launches Robotaxi service with no driver

In preparation for operation in new states, Tesla routinely lists job postings on its Careers website, which helps align potential employees with opportunities ahead of regulatory approvals. This is a strategy that allows Tesla to start operations immediately upon licensing for testing.

Tesla started hiring Vehicle Operators for Autopilot in Arizona and Nevada months before the company gained any sort of approvals from state governments for Robotaxi. However, those approvals eventually came in the form of testing licenses, which allow the company to perform validation ahead of its public launch.

Tesla begins validating Robotaxi in a new area, hinting at expansion

Now, Tesla has posted job listings for Vehicle Operators for Autopilot in two new states: Colorado and Illinois. The Colorado job listing is located in Aurora, a suburb of Denver. Tesla is looking for Robotaxi operators in Chicago as well.

These postings hint toward Tesla’s continuing efforts to expand Robotaxi to new places. Earlier this year, CEO Elon Musk said the company would like to have Robotaxi available to at least half of the U.S. population.

It has expanded significantly since its initial launch in late June, but it is still a far way off from where Tesla would like it to be by year’s end.

So far, Tesla has job listings for Autopilot Vehicle Operators in Arizona, California, Texas, Florida, Colorado, Nevada, and Illinois.

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