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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. 

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

Don’t hesitate to contact us with news tips. Just send a message to tips@teslarati.com to give us a heads up. 

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 urges New Jersey owners to oppose new bill that could block Robotaxi

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Credit: Grok

Tesla has launched a direct campaign targeting its customers in New Jersey, sending emails that warn of pending legislation that could effectively block true driverless technology in the state.

The email focuses on Senate Bill S.1677 and Assembly Bill A.3968, measures intended to create a three-year autonomous vehicle pilot program but laden with requirements that Tesla argues make unsupervised Robotaxis impossible.

According to the email, the bills impose “restrictions so severe that true driverless deployment would remain illegal.” Specific hurdles include mandates for human safety drivers during operations, multimillion-dollar insurance minimums, reportedly $5 million, and thresholds like 100,000 miles of demonstrated safe autonomous driving before any driverless approval.

Tesla contends these are arbitrary barriers that ignore real-world performance data and favor entrenched competitors over innovative technologies like its Full Self-Driving (FSD) system.

The push comes as Tesla has started expanding Robotaxi operations in states like Texas, where unsupervised vehicles are already providing rides in several cities. New Jersey, by contrast, risks falling behind. The company highlights in the email communication that more than 94 percent of serious crashes result from human error, meaning impairment, distraction, or fatigue. These are all problems that Robotaxis eliminate entirely.

In 2025, New Jersey recorded 582 traffic deaths, underscoring the human cost of delayed adoption.

Tesla’s outreach stresses the transformative potential of robotaxis. For families, they could offer safer school runs without drowsy or distracted drivers. For seniors and people with disabilities, robotaxis promise independence and reliable mobility.

In areas with limited public transit, they could deliver affordable, on-demand transportation, reducing congestion, emissions, and overall transportation costs. Economically, the company warns that restrictive rules could cost New Jersey jobs, innovation investment, and billions in potential growth as autonomous ride-hailing scales elsewhere.

Supporters of the legislation, including Sen. Andrew Zwicker, describe the pilot as a cautious framework with strong safety oversight, including incident reporting, expert task forces, and restrictions in sensitive zones like school areas. They view it as balancing innovation with public protection.

Tesla and pro-AV advocates counter that the bill lacks technology neutrality, creates insurmountable entry barriers for commercial deployment, and prioritizes process over outcomes — effectively functioning as a de facto ban on services like Robotaxi.

This latest clash echoes Tesla’s past battles in New Jersey over direct vehicle sales. The email directs owners to Tesla’s advocacy platform, where they can send customized messages to legislators calling for amendments: outcome-based safety standards, open competition, and clear pathways for fully driverless commercial operations.

As hearings approach, Tesla’s campaign frames the issue as a choice between protecting the status quo and embracing life-saving progress. With robotaxi technology already proving itself in permissive states, New Jersey owners are being asked to ensure their state doesn’t lock out the future of transportation.

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Tesla’s Navigation Nightmare: Why the easiest part of FSD might be the hardest

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Credit: TESLARATI

Turn-by-turn navigation is not new technology.

For over two decades, drivers have relied on Garmin, TomTom, and later smartphone apps like Google Maps and Waze to receive precise, reliable directions. These systems have guided millions safely through unfamiliar cities, highways, and backroads with remarkable effectiveness. They handle real-time traffic, construction detours, and complex intersections with minimal fuss.

Yet Tesla, the company that promised revolutionary Full Self-Driving (FSD), continues to struggle with this foundational capability. As FSD (Supervised) v14.3.4 has started rolling out to cars this week, navigation remains its glaring Achilles’ heel, undermining the entire autonomous vision.

Tesla Summon got insanely good in FSD v14.3.2 — Navigation? Not so much

Tesla’s FSD excels in many driving behaviors—smooth acceleration, confident lane changes in ideal conditions, and responsive handling of visible obstacles. However, when it comes to following a route accurately, the system falters repeatedly.

Owners report wrong turns, missed exits, inefficient routing through local roads instead of highways, phantom speed limit errors, and even directing vehicles to building rear entrances. Interventions for navigation issues often outnumber those for core driving maneuvers. Tesla has begun surveying owners specifically about these errors, acknowledging the problem after years of complaints.

Navigation is perhaps my biggest complaint when it comes to FSD, because sometimes, we do know better. Some of us have been living in our areas for our entire lives, but even those who have not have years or even decades of experience driving on local roads. We might know a little better about routing.

But the navigation mistakes are more than just FSD potentially taking a slightly different route that may or may not save you a few minutes. Sometimes, they’re genuinely mind-boggling.

This isn’t just annoying; it cascades into broader failures. A flawed route plan confuses the AI’s decision-making, leading to hesitant behavior, unnecessary disengagements, or dangerous maneuvers like attempting impossible U-turns or ignoring clear ramps. In a system meant to operate with minimal supervision, unreliable navigation erodes trust.

More often than not, false or plain incorrect navigation is what causes me to interrupt FSD operation. Unfortunately, I believe the latest FSD version is the worst example of it, and it leads me to believe that Tesla might be making some changes; they’ve just made them in the wrong direction.

It makes you wonder: Why is a company that has done so much with the progress of FSD and autonomy struggling so much with navigation, something that is not new and has been around a long time?

Multiple Data Sources

First, Tesla’s navigation relies on a fragile patchwork of multiple data sources—Google Maps, TomTom, OpenStreetMap, Valhalla, and its own fleet-derived data—stitched together rather than a single authoritative map. When these conflict on lane geometry, road status, or turn details, the system hesitates or chooses incorrectly.

Traditional GPS providers maintain centralized, regularly validated databases with professional curation and rapid updates. Tesla’s hybrid approach, while innovative in crowdsourcing, introduces inconsistencies that a purely vision-based or end-to-end AI approach may not easily reconcile in real time.

Persistent Learning

FSD seems to struggle with persistent learning from driver interventions.

Unlike consumer apps that quickly adapt to repeated corrections or user preferences (e.g., avoiding certain routes or remembering habitual detours), Tesla’s FSD often fails to internalize fixes on the same trip or across similar scenarios. Owners note making the same manual override multiple times without the routing engine updating its behavior meaningfully.

This stems from the neural architecture prioritizing real-time perception and control over long-term route memory and personalization, making navigation feel rigid and “opinionated” compared to the adaptive logic in Waze or Google Maps.

I noticed that when I asked Grok to try and get me home a certain way (a way that FSD routinely took in the past because it was the most efficient), it had to place a waypoint between my location at the time and my house. When I went to edit the waypoint out, as Grok had placed it for a way to get FSD to get off the highway at the right exit, it was stumped again, rerouted, and took a longer way home.

Reasoning, Scaling, and Intuition

Third, scaling navigation for unsupervised or robotaxi ambitions requires not just accuracy but adaptability and user-like reasoning. Current FSD often defaults to single routes that ignore driver preferences or real-world nuances like time-of-day traffic patterns. It fails to match the intuitive, context-aware planning that traditional systems have refined over the years.

Resolving navigation is critical for several reasons. Practically, it is the backbone of any autonomous journey: without trustworthy routing, the car cannot reliably reach destinations, rendering FSD useless for robotaxis or hands-free commutes. Safety depends on it—mismatched plans create hesitation in merges or intersections, increasing accident risk.

Economically, Tesla’s valuation and future hinge on FSD delivering unsupervised driving; persistent navigation flaws delay regulatory approval and erode consumer confidence. For owners who paid premiums for FSD, these issues represent unfulfilled promises. While it is unlikely Tesla will lose too many customers due to bad navigation, some will be frustrated with the constant need for human input.

Tesla has achieved miracles in electric vehicles and battery tech. Mastering turn-by-turn—technology Garmin nailed in the early 2000s—should not be this hard. By investing in tighter data integration, faster learning loops from interventions, and more intuitive routing algorithms, Tesla could close this gap.

Until then, FSD’s navigation struggles highlight a humbling truth: even the most ambitious innovator must sometimes master the basics before conquering the future.

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Tesla Cybertruck driver gets pickup seized for ‘legitimate concerns’ in UK

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A Tesla Cybertruck driver in the United Kingdom had their all-electric pickup seized by local police in the Greater Manchester area after the department cited “legitimate concerns.”

Last Thursday, police saw the pickup on the roads and decided to pull the driver over. Greater Manchester Police said:

“Whilst this may seem trivial to some, legitimate concerns exist around the safety of other road users or pedestrians if they were involved in a collision with the Cybertruck.”

The Cybertruck in question was, according to the BBC, registered and insured abroad and was confiscated. The driver, who is a UK resident, was reported.

The Greater Manchester Police Department then added:

“The Tesla Cybertruck is not road-legal in the UK and does not hold a certificate of conformity.”

The Cybertruck cannot be legally driven in the UK because it has no UK Type Approval for operation in the country. This is due to some safety concerns, which are related to its angular shape and design. The stainless steel exoskeleton has sharp edges and projections that violate UK/EU rules on pedestrian protection.

Tesla has considered creating what it referred to as an “international version” that would be approved for operation in Europe. However, there has been no real movement on that front by the company, as it has been focused on the Robotaxi rollout primarily.

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