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Tesla’s 4680 Kato Rd. facility has a top 10 capacity, and it’s not even close to finished

Credit: Tesla/YouTube

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Tesla CEO Elon Musk disclosed some details about the electric automaker’s 4680 cell plant last week. After stating that the facility is “probably in the top 10 battery cell factories on Earth despite being a pilot plant,” speculation began about how massive Tesla’s new facility that sits just across the street from the Fremont production facility is. Although it is in the top 10, it’s not even close to finished.

Tesla’s introduction of the 4680 battery cell came in September 2020 at the Battery Day event. Musk and others outlined the company’s roadmap for global EV dominance through the most important part of an electric car: the cell. The new cell has 500% more energy, six times the power of the old 2170 cells, and also offers dramatic range increases for more drive time between charges. It was truly revolutionary because Tesla is already the most notable company in electric cars.

With a considerable lead in the EV sector, Tesla was effectively announcing, “eat our (sustainable) dust” after showing the new 4680 cells. Some were skeptical, believing that the new cell wouldn’t be available for some time. Musk immediately silenced those doubts, indicating that the new cells had been deployed in working vehicles for months.

Credit: Tesla

The point is, the Kato Road facility, as it is widely known as, is one of the largest facilities in the world. While we are not sure what the current capacity is, if it is a top 10 facility in terms of capacity, we can speculate how big it may be.

According to Argus Media, the 10 largest battery cell plants range from 24 GWh per year to 70 GWh per year. The largest, an LG Chem facility in Wroclaw, Poland, has the 70 GWh capacity, leading BYD’s Qinghai, China plant by 10 GWh. Tesla and Panasonic’s joint venture at Gigafactory 1 in Nevada is a 35 GWh per year facility, making it the fifth-largest plant globally.

Credit: Argus Research

Because Tesla’s Kato Road facility is a pilot plant, we can likely assume that it is within the bottom half of this list. Especially with Gigafactory 1 being the fifth-largest, it is very likely that Kato Road is simply not producing as many cells or as much battery capacity as Giga 1, but it’s not to say that this won’t happen. The issue is that Tesla is still battery constrained, even with a large-scale facility in Nevada and with several third-party manufacturers pumping cells to the automaker at a massive rate. Kato Road will contribute to the solution to the constrained problem, and the facility will likely be significantly larger than Giga 1, considering the projects that Tesla plans to fulfill with the 4680 cells, the largest being the Tesla Semi.

The Semi is still not ready for production, Musk said on the Q4 Earnings Call last week. “We will have cells group in ourselves for Semi when we were producing the 4680 volume. But for example, Semi would use typically five times the number of cells that a car would use, but it would not sell for five times what a car would sell for. So it kind of doesn’t make…it would not make sense for us to do the Semi right now,” Musk said. The issue is cell availability, and since the Semi is going to equip Tesla’s newest 4680 project, it is safe to assume that Kato Road still has some expanding to do. If it is already a top 10 facility, yet it is still not ready to take on the massive Semi task, along with all of the other vehicles it will eventually fulfill, Kato Road may become a top 3 facility.

Ultimately, Tesla requires more cells. With no plans to eliminate purchases from third-party suppliers in the near-term, Tesla wants to increase purchases from those suppliers. CATL, Panasonic, and LG Chem could supply Tesla with more batteries moving forward, even with the Kato Road facility’s expansion and ramping up. The fact is, Tesla isn’t done solving the battery constraint issue, and it could battle with it for years to come. However, it won’t stop production from increasing because more cells are becoming available almost every day through supplier deals, increased outputs, and in-house manufacturing advancements, all of which make Tesla the company to beat for the foreseeable future.

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Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Tesla Robotaxi will be a 24/7 service: here’s when

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Credit: @AdanGuajardo/X

Tesla AI lead Ashok Elluswamy said this week that 24-hour Robotaxi service is close. Replying on X to a rider who wanted Cybercab trips all night, he wrote that the capability would arrive “next month or so” once “the next tech to merge on the v15 plan” is ready.

The comment landed on September 4, one day after Tesla opened public Cybercab rides in Austin. It is the clearest near-term timeline yet for overnight unsupervised operation. Tesla’s paid Robotaxi network currently runs from 6 a.m. to 10 p.m. seven days a week across Austin, Dallas, Houston, Miami, Orlando, and Tampa.

That 16-hour window is shorter than the 6 a.m. to 2 a.m. schedule the company used for much of the prior year.

Elluswamy did not name the specific feature or say whether the change would apply first to purpose-built Cybercabs, the existing Model Y fleet, or both. He also offered no city-by-city rollout list. The link to Full Self-Driving v15 is nevertheless significant.

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Tesla has described v15 as a step-change architecture with seven parallel improvement tracks and roughly ten times more parameters than earlier builds. Early versions of that software already operate on the Robotaxi fleet and contain about 40 percent of the planned gains.

By July 2026, the unsupervised fleet had logged more than 380,000 miles across six cities in two states with what the company called an impeccable safety record and no notable incidents caused by the vehicles themselves. Tesla has repeatedly argued that camera-based end-to-end neural networks, rather than extra sensors, are the core of the solution.

Overnight service would test that claim in lower-light conditions and would also raise vehicle utilization, a key variable for Robotaxi unit economics. The company has already begun using public Superchargers at night and is building dedicated Robotaxi charging sites.

Riders have asked why software must change if the cars already drive in the dark. The practical answer appears to be reliability and scale: Tesla has held back mass expansion until more of the v15 stack is merged, citing the need for higher confidence before putting thousands of unoccupied vehicles on streets around the clock.

If the next module arrives on the timetable Elluswamy sketched, 24-hour service could begin in October 2026 in at least some markets.

That would mark a shift from a daytime-bounded pilot to a service that can run whenever demand exists, including the late-night hours that have so far remained out of reach.

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Tesla Full Self-Driving will now overtake manual driving to avoid disaster

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Credit: Tesla

Tesla is beginning to roll out Full Self-Driving Supervised v14.3.9 with a new active safety layer that can take control even when the driver is operating the car manually.

Tesla AI said the software can activate FSD on the driver’s behalf when an imminent collision is detected and Automatic Emergency Braking may not be enough. It may also engage if the system detects heavy distraction or an accidental FSD disengagement.

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The capability is essentially Automatic Collision Evasion. However, unlike conventional AEB, which mainly applies the brakes in a straight line, this feature can use steering, braking, and acceleration together if the car calculates that stopping alone will not prevent impact and a safer path exists. The system may change lanes or move toward a shoulder when conditions allow, then continue driving after the immediate threat is handled rather than simply coming to a stop.

The intervention is meant as a last-resort safety net, not a replacement for attentive driving.

Tesla Full Self-Driving v14.3.7 early review: FSD saved me from an accident

Tesla’s own description still frames FSD as supervised assistance. Secondary reports on internal release notes say the feature can fire while the car is being driven manually if cabin-camera monitoring suggests the driver is not sufficiently attentive, such as reaching toward the back seat, or if FSD appears to have been turned off unintentionally.

After the emergency maneuver, the car is expected to alert the driver and request a return to manual control.

The safety case is straightforward. Many collisions happen in the last second because a driver is looking away, fumbles a control, or faces an obstacle that braking cannot fully solve. A system that can both recognize that AEB is insufficient and execute a coordinated evasive path can reduce those remaining high-severity events.

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Re-engaging after accidental disengagement also addresses a practical failure mode: a small steering nudge that drops FSD at the worst moment. The advantage is a background safety net that uses the same vision stack already running in v14, instead of leaving the car solely to emergency braking once the driver is no longer in command.

The feature still depends on FSD being enabled and, according to reports, an active FSD purchase or subscription. It does not make the vehicle unsupervised. Drivers remain responsible, and Tesla has not published how often the system is expected to intervene or how it will handle false positives.

If the rollout is conservative and the false-alarm rate stays low, the update is a meaningful step: FSD is no longer only a feature the driver turns on. In the rare moments when disaster is already forming, it can step in.

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Tesla Cybercab launch catches NHTSA’s attention who wants to know more

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(Credit: Teslarati)

Tesla launched the all-electric, steering wheel-less, and pedal-less Cybercab last night at a quiet and small event in downtown Austin, Texas.

The launch, which marked the beginning of unsupervised ride-hailing for Tesla’s Robotaxi platform with Cybercab, has already caught the attention of the National Highway Traffic Safety Administration (NHTSA) who has more questions.

NHTSA opened an Audit Query (AQ) into the Cybercab’s Federal Motor Vehicle Safety Standards (FMVSS) certification that Tesla gave the vehicle. Manufacturers self-certify vehicles much of the time to avoid excessive regulatory delays.

Tesla Cybercab interior, note the lack of steering wheel and pedals. (Credit: @niccruzpatane/X< /a>)

However, the agency needs more information; it said in a summary:

“On September 3, 2026, Tesla began commercial deployment with a small number of its Cybercab vehicles in Austin, Texas. Tesla notified the Agency that it certified those Cybercab vehicles as compliant with all applicable Federal Motor Vehicle Safety Standards (FMVSS). Tesla also notified the Agency that it plans to gradually expand commercial deployment of the Cybercab to include additional vehicles and locations.”

It also went on to state that the Cybercab lacks traditional automotive controls, which is a groundbreaking move. The process is entirely new to the NHTSA, which gives the agency some leverage to put Tesla’s launch under a microscope:

“The vehicles lack permanently attached, conventional manual controls, such as a brake pedal, gas pedal, steering wheel, and mirrors. NHTSA is opening this AQ to examine the process and technical data on which Tesla relied when certifying the Cybercab and related issues. Among other things, NHTSA will consider the extent to which Tesla’s certification depended on determinations that certain FMVSS are inapplicable to the Cybercab.”

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Tesla has added 45 Cybercab units to its fleet of Robotaxi-enabled cars in Austin, according to public documents the company submitted to the State of Texas over the past week. Enabling this level of self-driving is something Tesla has worked toward for many years, and now that it is finally here, it seems more than reasonable that regulatory agencies will have some questions.

Many outlets might try to frame this as a negative, but it is truly an agency looking to gain more information about groundbreaking tech that Tesla has been developing for years.

In an effort to keep riders, pedestrians, and property safe, any and all data accumulated from these first days, weeks, and months of rides will likely be shared with the NHTSA to enable broader rollout strategies across the United States and more in the future.

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