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Tesla’s 4680 battery cell pilot production line hits 70-80% yield: report

Credit: Tesla Inc.

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Tesla has a number of programs that have the potential to change markets, and one of these is arguably the 4680 cells. Created using a dry electrode process and optimized for price and efficiency, the 4680 batteries could very well be the key to Tesla’s possible invasion of the mainstream auto and energy market. If Tesla pulls off its 4680 production ramp, its place at the summit of the sustainable energy market would be all but ensured. 

Unfortunately, Tesla’s publicly disclosed target for the 4680 cells’ production ramp appears to have been made on “Elon Time.” This means that during Battery Day last year, Tesla’s target of hitting a capacity of 10 GWh by late September 2021 included some optimistic assumptions. Similar to other projects like Elon Musk’s Alien Dreadnaught factory, however, the pilot production of the 4680 cells have met some challenges. 

Credit: Tesla Inc.

Tesla admitted to these difficulties during the Q2 2021 earnings call, when Elon Musk explained that one of the main challenges in the 4680 cell production ramp was related to the batteries’ calendaring, or the process when the dry cathode material is squashed to a particular height. Partly due to the use of nickel in the 4680 cells, which are extremely hard, some of the calendar rolls end up being dented. 

This was an issue that presented itself only in the pilot 4680 line, not during the bench and lab stages. Tesla Senior Vice President of Powertrain and Energy Engineering Drew Baglino, however, emphasized that the challenges in the Kato Road facility are an engineering problem and not a science issue. This meant that with enough work and optimization, Tesla should be able to address the calendaring issues of the dry battery cells. 

Credit: evmadrid/Instagram

Citing sources familiar with the matter, Tesla investor and host of YouTube’s Hyperchange channel Galileo Russell recently shared some details suggesting that Tesla may have hit some breakthroughs with the production of the 4680 cells. As per the Tesla investor, the production yield of the 4680 cells has reportedly risen to about 70-80%, up from just about 20% last year. This means that a decreasing portion of the 4680 cells produced today are seeing issues, and Tesla’s pilot battery line at Kato Road is starting to close in on the acceptable yields of factories like Giga Nevada. 

While the delays in the 4680 cells appear to have affected the rollout of products like the Cybertruck and the Semi, it is starting to become evident that Tesla is about to hit some respectable battery output from its pilot line in California. Fortunately, the company has already initiated some contingencies that address the 4680 cells’ delays. The production of the Model Y in Giga Berlin and Giga Texas would be launched with 2170 battery packs, for example, at least until the 4680 cells are available. 

Watch Hyperchange‘s feature on Tesla’s 4680 battery production challenges in the video below.  

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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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Tesla dominates in the UK with Model Y and Model 3 leading the way

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Credit: Tesla China

Tesla is dominating in the United Kingdom so far through 2025, and with about two weeks left in the year, the Model Y and Model 3 are leading the way.

The Model Y and Model 3 are the two best-selling electric vehicles in the United Kingdom, which is comprised of England, Scotland, Wales, and Northern Ireland, and it’s not particularly close.

According to data gathered by EU-EVs, the Model Y is sitting at 18,890 units for the year, while the Model 3 is slightly behind with 16,361 sales for the year so far.

The next best-selling EV is the Audi Q4 e-tron at 10,287 units, lagging significantly behind but ahead of other models like the BMW i4 and the Audi Q6 e-tron.

The Model Y has tasted significant success in the global market, but it has dominated in large markets like Europe and the United States.

For years, it’s been a car that has fit the bill of exactly what consumers need: a perfect combination of luxury, space, and sustainability.

Both vehicles are going to see decreases in sales compared to 2024; the Model Y was the best-selling car last year, but it sold 32,610 units in the UK. Meanwhile, the Model 3 had reached 17,272 units, which will keep it right on par with last year.

Tesla announces major milestone in the United Kingdom

Tesla sold 50,090 units in the market last year, and it’s about 8,000 units shy of last year’s pace. It also had a stronger market share last year with 13.2 percent of the sales in the market. With two weeks left in 2025, Tesla has a 9.6 percent market share, leading Volkswagen with 8 percent.

The company likely felt some impact from CEO Elon Musk’s involvement with the Trump administration and, more specifically, his role with DOGE. However, it is worth mentioning that some months saw stronger consumer demand than others. For example, sales were up over 20 percent in February. A 14 percent increase followed this in June.

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Tesla Insurance officially expands to new U.S. state

Tesla’s in-house Insurance program first launched back in late 2019, offering a new way to insure the vehicles that was potentially less expensive and could alleviate a lot of the issues people had with claims, as the company could assess and repair the damage itself.

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Credit: Tesla Insurance

Tesla Insurance has officially expanded to a new U.S. state, its thirteenth since its launch in 2019.

Tesla has confirmed that its in-house Insurance program has officially made its way to Florida, just two months after the company filed to update its Private Passenger Auto program in the state. It had tried to offer its insurance program to drivers in the state back in 2022, but its launch did not happen.

Instead, Tesla refiled the paperwork back in mid-October, which essentially was the move toward initiating the offering this month.

Tesla’s in-house Insurance program first launched back in late 2019, offering a new way to insure the vehicles that was potentially less expensive and could alleviate a lot of the issues people had with claims, as the company could assess and repair the damage itself.

It has expanded to new states since 2019, but Florida presents a particularly interesting challenge for Tesla, as the company’s entry into the state is particularly noteworthy given its unique insurance landscape, characterized by high premiums due to frequent natural disasters, dense traffic, and a no-fault system.

Tesla partners with Lemonade for new insurance program

Annual average premiums for Florida drivers hover around $4,000 per year, well above the national average. Tesla’s insurance program could disrupt this, especially for EV enthusiasts. The state’s growing EV adoption, fueled by incentives and infrastructure development, aligns perfectly with Tesla’s ecosystem.

Moreover, there are more ways to have cars repaired, and features like comprehensive coverage for battery damage and roadside assistance tailored to EVs address those common painpoints that owners have.

However, there are some challenges that still remain. Florida’s susceptibility to hurricanes raises questions about how Tesla will handle claims during disasters.

Looking ahead, Tesla’s expansion of its insurance program signals the company’s ambition to continue vertically integrating its services, including coverage of its vehicles. Reducing dependency on third-party insurers only makes things simpler for the company’s automotive division, as well as for its customers.

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Tesla Full Self-Driving gets sparkling review from South Korean politician

“Having already ridden in an unmanned robotaxi, the novelty wasn’t as strong for me, but it drives just as well as most people do. It already feels like a completed technology, which gives me a lot to think about.”

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Credit: Soyoung Lee | X

Tesla Full Self-Driving got its first sparkling review from South Korean politician Lee So-young, a member of the country’s National Assembly, earlier this week.

Lee is a member of the Strategy and Finance Committee in South Korea and is a proponent of sustainable technologies and their applications in both residential and commercial settings. For the first time, Lee was able to utilize Tesla’s Full Self-Driving technology as it launched in the country in late November.

Her thoughts on the suite were complimentary to the suite, stating that “it drives just as well as most people do,” and that “it already feels like a completed technology.”

Her translated post says:

“Finally, today I got to experience Tesla FSD in Seoul. Thanks to the Model S sponsored by JiDal Papa^^, I’m truly grateful to Papa. The route was from the National Assembly -> Mangwon Market -> Hongik University -> back to the National Assembly. Having already ridden in an unmanned robotaxi, the novelty wasn’t as strong for me, but it drives just as well as most people do. It already feels like a completed technology, which gives me a lot to think about. Once it actually spreads into widespread use, I feel like our daily lives are going to change a lot. Even I, with my license gathering dust in a drawer, don’t see much reason to learn to drive a manual anymore.”

Tesla Full Self-Driving officially landed in South Korea in late November, with the initial launch being one of Tesla’s most recent, v14.1.4.

It marked the seventh country in which Tesla was able to enable the driver assistance suite, following the United States, Puerto Rico, Canada, China, Mexico, Australia, and New Zealand.

It is important to see politicians and figures in power try new technologies, especially ones that are widely popular in other regions of the world and could potentially revolutionize how people travel globally.

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