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Tesla’s 4680 battery ramp may experience a “Death Valley” start, but it will be overcome: expert

Credit: @Gfilche/Twitter

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To state that Tesla’s future lies in the success or failure of the 4680 battery is not an understatement. Without 4680 cells, Tesla’s efforts to create an affordable car at a price point beneath the Model 3 would likely be for naught. But if the company succeeds in ramping the production of its 4680 cells, Tesla could very well pave the way for electric vehicles to become the dominant form of personal transportation in the decades to come. 

Getting there would not be easy. Tesla formally announced its 4680 battery project in September 2020, and since then, the company has been working hard to ramp the production of the next-generation cell. Tesla produced its one millionth 4680 cell in January. That’s a milestone on its own, but it does show that the company still has a long way to go before it can fully ramp its new battery. 

Industry researcher Benchmark Mineral Intelligence estimates that one million 4680 cells are enough for just about 1,200 Model Ys. Tesla intends to produce far more than that per week in Gigafactory Texas alone. 

Tesla’s 4680 cells are not designed like conventional batteries, and they are not made like traditional cells either. Tesla plans to use a new manufacturing technology called dry electrode coating, which was obtained from the company’s acquisition of Maxwell Technologies in 2019. Dry electrode manufacturing would allow Tesla to skip a conventional step in traditional battery production, which should lower costs significantly

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While Tesla acquired the technology, the innovations involved in the mass-production of 4680 cells using dry electrode coating are a massive challenge. Elon Musk has noted that the factory equipment for the process alone “doesn’t exist,” so they still have to be made. 

Shirley Meng, a University of Chicago professor who previously worked with Maxwell, noted that Tesla’s 4680 battery efforts could change the industry. She also emphasized that Tesla’s challenges in mass-producing the next-generation battery would be immense. “He (Elon Musk) is changing the way how battery manufacturing is done. It’s really, really difficult to manufacture at a speed and at scale,” she said. She also stated that Tesla may have to experience a “Death Valley” start to scaling up the dry electrode process for 4680 cells. 

She does, however, believe that Tesla would overcome these difficulties. 

Other experts and longtime followers of the company seem to agree on the difficulty involved in developing and ramping a new type of battery cell. Caspar Rawles, chief data officer at Benchmark Mineral Intelligence, noted that fine-tuning the production equipment for battery production alone is an extremely long process, and one that challenges even the industry’s veterans. “There’s a very long process of fine-tuning the equipment before you can get to volume production. Battery production is hard, even hard for experienced suppliers,” he said. 

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This definitely seems to be the case with Panasonic. The Japanese tech conglomerate has been a longtime partner of Tesla, and it already operates Gigafactory Nevada with the EV maker. However, recent comments from Kazuo Tadanobu, the CEO of Panasonic’s energy division, revealed that even Panasonic had to take its time to develop its 4680 batteries. Tadanobu noted that Tesla has already deemed Panasonic’s 4680 cells viable for use, but mass production of the new batteries is still expected to start by the fiscal year ending in March 2024.  

Tesla’s 4680 cells are expected to be used in vehicles like the Tesla Semi, the Cybertruck, and the company’s flagship supercar, the new Roadster. The next-generation batteries are also expected to be utilized in Tesla’s next big project, the production of an affordable $25,000 electric car.  

*Quotes courtesy of Reuters.

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

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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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Elon Musk

Tesla Full Self-Driving’s newest behavior is the perfect answer to aggressive cars

According to a recent video, it now appears the suite will automatically pull over if there is a tailgater on your bumper, the most ideal solution for when a driver is riding your bumper.

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Credit: Tesla

Tesla Full Self-Driving appears to have a new behavior that is the perfect answer to aggressive drivers.

According to a recent video, it now appears the suite will automatically pull over if there is a tailgater on your bumper, the most ideal solution for when a driver is riding your bumper.

With FSD’s constantly-changing Speed Profiles, it seems as if this solution could help eliminate the need to tinker with driving modes from the person in the driver’s seat. This tends to be one of my biggest complaints from FSD at times.

A video posted on X shows a Tesla on Full Self-Driving pulling over to the shoulder on windy, wet roads after another car seemed to be following it quite aggressively. The car looks to have automatically sensed that the vehicle behind it was in a bit of a hurry, so FSD determined that pulling over and letting it by was the best idea:

We can see from the clip that there was no human intervention to pull over to the side, as the driver’s hands are stationary and never interfere with the turn signal stalk.

This can be used to override some of the decisions FSD makes, and is a great way to get things back on track if the semi-autonomous functionality tries to do something that is either unneeded or not included in the routing on the in-car Nav.

FSD tends to move over for faster traffic on the interstate when there are multiple lanes. On two-lane highways, it will pass slower cars using the left lane. When faster traffic is behind a Tesla on FSD, the vehicle will move back over to the right lane, the correct behavior in a scenario like this.

Perhaps one of my biggest complaints at times with Full Self-Driving, especially from version to version, is how much tinkering Tesla does with Speed Profiles. One minute, they’re suitable for driving on local roads, the next, they’re either too fast or too slow.

When they are too slow, most of us just shift up into a faster setting, but at times, even that’s not enough, see below:

There are times when it feels like it would be suitable for the car to just pull over and let the vehicle that is traveling behind pass. This, at least up until this point, it appears, was something that required human intervention.

Now, it looks like Tesla is trying to get FSD to a point where it just knows that it should probably get out of the way.

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Tesla Megapack powers $1.1B AI data center project in Brazil

By integrating Tesla’s Megapack systems, the facility will function not only as a major power consumer but also as a grid-supporting asset.

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Credit: Tesla

Tesla’s Megapack battery systems will be deployed as part of a 400MW AI data center campus in Uberlândia, Brazil. The initiative is described as one of Latin America’s largest AI infrastructure projects.

The project is being led by RT-One, which confirmed that the facility will integrate Tesla Megapack battery energy storage systems (BESS) as part of a broader industrial alliance that includes Hitachi Energy, Siemens, ABB, HIMOINSA, and Schneider Electric. The project is backed by more than R$6 billion (approximately $1.1 billion) in private capital.

According to RT-One, the data center is designed to operate on 100% renewable energy while also reinforcing regional grid stability.

“Brazil generates abundant energy, particularly from renewable sources such as solar and wind. However, high renewable penetration can create grid stability challenges,” RT-One President Fernando Palamone noted in a post on LinkedIn. “Managing this imbalance is one of the country’s growing infrastructure priorities.”

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By integrating Tesla’s Megapack systems, the facility will function not only as a major power consumer but also as a grid-supporting asset.

“The facility will be capable of absorbing excess electricity when supply is high and providing stabilization services when the grid requires additional support. This approach enhances resilience, improves reliability, and contributes to a more efficient use of renewable generation,” Palamone added.

The model mirrors approaches used in energy-intensive regions such as California and Texas, where large battery systems help manage fluctuations tied to renewable energy generation.

The RT-One President recently visited Tesla’s Megafactory in Lathrop, California, where Megapacks are produced, as part of establishing the partnership. He thanked the Tesla team, including Marcel Dall Pai, Nicholas Reale, and Sean Jones, for supporting the collaboration in his LinkedIn post.

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Starlink powers Europe’s first satellite-to-phone service with O2 partnership

The service initially supports text messaging along with apps such as WhatsApp, Facebook Messenger, Google Maps and weather tools.

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Credit: SpaceX

Starlink is now powering Europe’s first commercial satellite-to-smartphone service, as Virgin Media O2 launches a space-based mobile data offering across the UK.

The new O2 Satellite service uses Starlink’s low-Earth orbit network to connect regular smartphones in areas without terrestrial coverage, expanding O2’s reach from 89% to 95% of Britain’s landmass.

Under the rollout, compatible Samsung devices automatically connect to Starlink satellites when users move beyond traditional mobile coverage, according to Reuters.

The service initially supports text messaging along with apps such as WhatsApp, Facebook Messenger, Google Maps and weather tools. O2 is pricing the add-on at £3 per month.

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By leveraging Starlink’s satellite infrastructure, O2 can deliver connectivity in remote and rural regions without building additional ground towers. The move represents another step in Starlink’s push beyond fixed broadband and into direct-to-device mobile services.

Virgin Media O2 chief executive Lutz Schuler shared his thoughts about the Starlink partnership. “By launching O2 Satellite, we’ve become the first operator in Europe to launch a space-based mobile data service that, overnight, has brought new mobile coverage to an area around two-thirds the size of Wales for the first time,” he said.

Satellite-based mobile connectivity is gaining traction globally. In the U.S., T-Mobile has launched a similar satellite-to-cell offering. Meanwhile, Vodafone has conducted satellite video call tests through its partnership with AST SpaceMobile last year.

For Starlink, the O2 agreement highlights how its network is increasingly being integrated into national telecom systems, enabling standard smartphones to connect directly to satellites without specialized hardware.

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