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Experts explain Tesla’s 4680 battery production ramp and challenges

Image Credit: Falk Melzer

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Tesla has been pretty open about the idea that its next-generation of vehicles and its 20 million EV target for 2030 would rely on its ability to scale its 4680 battery production. This task, at least according to experts, has proven to be especially challenging. 

Unveiled during Battery Day nearly two years ago, 4680 cells are expected to provide Tesla with substantial manufacturing cost reductions and efficiencies. According to statements from several experts in the field, the use of larger cells and a dry-coat electrode process could enable Tesla to halve the cost of a Model Y battery.

Twelve experts who are reportedly close to Tesla, or at least familiar with the company’s new battery technology, shared their insights with Reuters. Among the 12 experts, nine reportedly have close ties to Tesla, while three have examined the company’s previous battery technology thoroughly through an extensive teardown. 

According to the publication’s sources, Tesla is only halfway towards its goal of successfully rolling out its 4680 cells. While the EV maker already sees benefits from the use of larger cells, Tesla is still reportedly seeing challenges with scaling its dry-coat electrode process. 

This, according to the experts, was because Tesla’s dry-coat electrode process is so new and unproven that the company is still having trouble scaling its operations to the point where savings become substantial. Still, the publication’s sources have stated that Tesla would probably still be able to fully implement its 4680 cells’ dry coat electrode process next year. 

2019 Nobel laureate and lithium-ion battery pioneer Stan Whittingham believes that Tesla would ultimately solve the challenges associated with its 4680 battery production ramp, though he also noted that Elon Musk might have been too optimistic with his target timeframe for the next-generation batteries’ rollout. “I think he will solve it, but it won’t be as quick as he likes. It’s going to take some time to really test it,” Whittingham said.

Reuters‘ sources noted that if all the potential efficiencies from the use of 4680 batteries are realized, the manufacturing cost for the Model Y’s 4680 structural battery could fall to just about $5,000-$5,500 — roughly half the cost of a 2170 pack. So far, Tesla is reportedly seeing about $2,000 to $3,000 worth of cost savings, mainly due to its use of bigger cells. 

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With Tesla’s 2170 battery packs, the company reportedly uses about 4,400 cells for the Model Y. The 2170 packs also require 17,600 points that need to be welded — about four welds per cell — to create a battery that can be integrated into the all-electric crossover. This is reduced significantly with the use of 4680 cells. The experts noted that Tesla only needs 830 cells for its Model Y 4680 structural pack, and since there are only two weld points for each cell, the total weld points per vehicle drops to just 1,660 points. 

But while Tesla has made tons of headway with its 4680 batteries, and while the company already sees savings due to its use of larger cells, the EV maker still needs to master and scale its dry electrode process. Once that’s done, Tesla could effectively attain the holy grail of its next-generation batteries. “Bulking up the battery cell helped a lot in boosting efficiency, but pushing for 50% cost savings for the cell as a whole is another matter. That will depend on whether Tesla can deploy the dry-coating process successfully in a factory,” one of Reuters‘ sources said. 

Don’t hesitate to contact us with news tips. Just send a message to simon@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 Roadster unveiling nears, and it will fly: The Information

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(Credit: Dami Kolz/Twitter)

Tesla is nearing its long-awaited unveiling of the all-electric Tesla Roadster, a new report from The Information claims, as the company has said several times this year that the event would take place “soon.”

Now, it appears there is movement on Tesla’s end regarding when it will happen.

The report says that Tesla will unveil the Roadster as soon as this month with a SpaceX version that will utilize cold-gas thrusters to help the vehicle float for a short period of time. This is something CEO Elon Musk has talked about with the Roadster for years.

Additionally, due to the delays, Tesla explored “a variety of designs” for the Roadster, potentially planning to abandon the design it showed off for the first time in 2017 and adopting an entirely new aesthetic.

According to The Information, Tesla considered utilizing a repurposed Model S Plaid and even wanted to upgrade the look to something like a Lamborghini Countach.

Elon Musk teases Tesla Roadster unveiling once again

We’ve heard all of these things before, including teases about the date and how “soon” the Roadster will finally be ready to be shown off to the world (for the second time). Musk said that the event would occur in April, then May, then Chief Designer Franz von Holzhausen continued to say it would be coming “soon.”

We do expect to see the Roadster by the end of the year, and now with this new report swirling, it appears it could be sooner rather than later.

The wait has been incredibly long, but there is likely a good reason for it. Tesla’s desire to make the Roadster the craziest vehicle on the road was non-negotiable, and it likely took a lot of time and resources to develop and perfect into something that was safe and suitable for a vehicle like this.

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Featured

Tesla finally got its Nevada Robotaxi Permit but with a few catches hard to miss

Nevada granted Tesla’s robotaxi permit, but capped the fleet at just ten vehicles for now.

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Concept art of a Tesla Cybercab in Las Vegas Strip as rendered via Grok

Tesla has received its robotaxi permit in Nevada, more than two months after regulators closed the public comment period on the company’s application. News of the approval surfaced Wednesday night when Tesla investor and longtime company watcher Sawyer Merritt posted a copy of the interim order, and the Nevada Transportation Authority’s own carrier registry now lists the permit, AVNC Permit 002 under Docket 26-05015, as active for Tesla Robotaxi, LLC.

Tesla asked Nevada in June for authority to run up to 5,000 vehicles in Clark County within a year, however the permit the NTA issued is initially capping Tesla at ten fully autonomous vehicles and confines them to a defined geofence along the Las Vegas Strip corridor. Any expansion of that operating area, or any increase to the fleet size, requires the NTA’s approval first.

The order also sets rules that look more restrictive than what Tesla runs in Austin. Rides are barred on roads with posted speed limits above 45 miles per hour, pickups are off limits within a quarter mile of Harry Reid International Airport without separate authorization, and every vehicle has to carry visible “Robotaxi” markings while notifying riders before each trip that no one is driving. The order also requires “appropriate human supervision”, language that suggests Nevada isn’t ready to let Tesla offer the rides without a safety monitor that it has run in parts of Austin since January. As with standard protocol with robotaxi services, Tesla must report any accident, system failure, or vehicle that becomes stranded on a Nevada road within five business days.

Tesla is entering a market Nevada already knows well. Zoox, the Amazon owned robotaxi company, has run its own autonomous vehicle permit in the state since last year, building up to roughly 100 vehicles and 350,000 rides along the Strip. That history likely explains why the NTA started Tesla at ten cars rather than the fleet size the company asked for. The agency has a template for scaling a permit up once a company proves out its safety record.

Tesla’s Nevada application first surfaced in June, when the company filed for the permit alongside plans for a maintenance hub in southwest Las Vegas. The company has said it won’t meaningfully scale its robotaxi fleet anywhere until FSD v15 ships, expected in late 2026 or early 2027, which makes the ten vehicle cap less of a constraint today than it might look on paper. For now, Tesla has the legal right to start Nevada rides. Whether it starts before FSD v15 arrives is a separate question the permit doesn’t answer.

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Energy

Tesla launches Powerwall Lease for affordable home backup

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Credit: Tesla

Tesla Energy has introduced the Powerwall Lease in conjunction with Tesla Electric, making the service available in Texas. This new option delivers whole-home backup power using two Powerwall units for a net monthly cost of $35 after credits, accompanied by a low fixed electricity rate.

Under the lease terms, customers pay a one-time order fee of $100. The base lease payment for the two Powerwalls is approximately $122 per month during the first year, subject to a 3 percent annual escalator thereafter. Enrollment in a qualifying Tesla Electric Backup plan or Virtual Power Plant plan provides an $87 monthly credit.

This credit lowers the effective cost to roughly $35 per month plus applicable tax.

Installation of the standard system carries no additional charge. The package features Storm Watch for outage protection and allows complete management through a single Tesla application. The system supplies continuous whole-home backup capability.

The Powerwall system enables households to maintain electricity during severe storms that disrupt the utility grid. When outages occur, the batteries automatically provide seamless backup power to the home.

Tesla announces 100k Powerwalls are participating in Virtual Power Plants

Tesla Storm Watch monitors weather forecasts and ensures the units are fully charged ahead of anticipated severe weather events so that power remains available throughout the disruption, keeping lights, refrigeration, and other essential systems operating without interruption.

Availability is restricted to select Texas locations where retail electric choice exists. Participants must lease exactly two Powerwall units and maintain continuous enrollment with Tesla Electric. Solar panels cannot be included under this particular lease arrangement.

The monthly credit activates automatically once the system is installed, receives permission to operate, and enrollment is confirmed. To retain the credit, customers are required to stay enrolled in Tesla Electric and fulfill all program conditions.

Nonstandard installations that involve electrical upgrades or special permitting may lead to extra expenses and might impact eligibility for the credit, so be sure to check with either your installer or Tesla to ensure you will still qualify.

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