News
Tesla 4680 cells compared with BYD Blade and CATL Qilin structural batteries
The battle for the dominance of the electric vehicle sector would likely be determined by the market’s key battery makers. With this in mind, companies such as BYD, CATL, and Tesla — all of whom are exploring the structural battery form factor — have the chance to become the trailblazers of the next generation of electric car batteries.
During its Battery Day event, Tesla announced its 4680 cells, which are used alongside the company’s structural battery pack. BYD, on the other hand, has also released its Blade batteries, which also adopt a non-modular approach. CATL’s Qilin batteries are in the same segment, with its structural battery design.
Electric vehicle battery enthusiast Jordan Giesige of YouTube’s The Limiting Factor channel recently conducted a comparison of the advantages and disadvantages of Tesla, BYD, and CATL’s next-generation structural packs. Each battery pack was evaluated according to several factors, such as design, rigidity, packing and energy density, and safety, before being ranked. It should be noted that the figures used in the comparisons are drawn from estimates and materials released by Tesla, BYD, and CATL themselves, not current real-world observations.
As noted by Giesige, Tesla’s 4680 structural battery packs utilize hundreds of cylindrical cells with a cooling ribbon in between every other row of cells. A lid is then placed on top and polyurethane foam is injected into the pack. This polyurethane hardens, and the combination of the foam and the battery cells forms a rigid, honeycomb-type structure.
CATL Qilin batteries, which could be fitted with both nickel and iron-based cells, integrate thermal pads, the liquid cooling plate, and the cross bracing to create what could be described as structural cooling. The structural cooling is placed between each row of prismatic battery cells, and the cells themselves are placed into the pack directly without any modules. BYD Blade batteries use iron-based prismatic cells, though these cells are longer and thinner than those used by CATL. The cells are then stretched across the BYD Blade battery pack, allowing the cells themselves to replace conventional steel beams.
In the rankings of the next-generation batteries, the YouTube host noted that Tesla’s 4680 structural battery pack would likely be the most rigid among its peers. Tesla’s 4680 pack loses out in terms of packing density, however, as BYD and CATL’s use of prismatic cells maximizes volumetric energy density. With this in mind, and considering that CATL’s Qilin batteries can be fitted with high-energy density nickel-based cells, a nickel-based Qilin battery would likely be more energy dense than a nickel-based Tesla 4680 pack or a BYD Blade structural battery, which uses less energy dense iron-based cells.
As for cooling, Giesige noted that the BYD Blade batteries’ plate cooling would likely fall short of the Tesla 4680 pack and CATL Qilin battery’s cooling systems. In its marketing materials, CATL highlighted that cooling the sides of the Qilin battery increases the pack’s cooling area four times. Tesla’s 4680 battery also uses better cooling than BYD’s Blade batteries with its side cooling system, though it would likely not be as good as the cooling of CATL’s Qilin structural packs.
While BYD’s Blade batteries lose out in cooling, they are also likely the safest among its peers. This is because the BYD Blade battery uses iron-based cells, which have a higher decomposition and lower heat release temperature than the nickel-based cells used in Tesla’s 4680 cells and CATL’s nickel-based Qilin batteries. An iron-based Qilin battery comes second to the BYD Blade, partly due to its use of shorter and thicker prismatic cells, which may trap more heat.
A Qilin pack with nickel-based cells was ranked last in terms of safety by the battery enthusiast, as Tesla’s 4680 pack with nickel-based cells features several safety systems, such as an overpressure mechanism on the bottom of the cells themselves. Since 4680 cells are also smaller than the prismatic cells used in the BYD Blade and CATL Qilin, they contain less energy. The 4680 cells themselves are enclosed in a thick shell as well, which are about 2-3 times thicker than a conventional battery.
Overall, Giesige noted that Tesla’s 4680 cells are likely the best all-rounder compared to its peers in the structural battery segment. The overall scores of the BYD Blade and CATL Qilin batteries bode well for Tesla’s future, however, as the companies could become suppliers of the EV maker in the future. CATL is already supplying Tesla with LFP batteries today, and BYD is heavily rumored to be a Tesla supplier as well. In a way, the analysis of the next-generation structural EV batteries shows that Tesla is not alone in pushing the battery industry forward.
Watch The Limiting Factor‘s full analysis in the video below.
Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.
A Texas man has been arrested and charged with manslaughter after his Tesla crashed into a home last month, striking a woman inside and killing her. The driver, Michael Butler, claimed the vehicle was in self-driving mode, but information from Tesla shows that Butler overrode the system.
Butler was arrested on Wednesday and booked at the Harris County, Texas, jail. He remained in custody through Thursday and Friday; he did not enter a plea, and his next court hearing is scheduled for Monday.
Tesla finally clarifies fatal Texas crash, confirms driver manually overrode acceleration
There are a handful of new clues in the case that could clear Tesla of any wrongdoing, especially as the woman who was killed’s family, the Avilas, filed a wrongful death lawsuit against Tesla and Butler, seeking at least $1 million in damages.
Charging documents from the Harris County prosecutor now show that Butler, who was working DoorDash the evening of the accident, had been using Full Self-Driving mode without incident through the duration of multiple deliveries that evening.
In the moments leading up to the crash, while in FSD and approaching a left turn, Butler pressed the accelerator pedal, overriding FSD’s speed control, and continued to push it until it reached 100 percent. This caused rapid acceleration; the brake pedal was never pressed, and there is no data to show that Butler aimed to turn away from the curb or house.
The charging documents state:
“I noted that the brake pedal was never pressed in the final minute before the crash. I also did not see any data to indicate that the driver attempted to turn away from the curb that he eventually struck. Further, I observed that no mechanical error was detected or recorded by the vehicle before BUTLER and the Tesla struck the curb.”
Additionally, a forensic analysis of Butler’s phone showed that he searched Google around the time of the crash with queries questioning why FSD was “too timid,” “not aggressive enough,” and even searched, “FSD is not aggressive enough for city driving.”
The documents outlined this:
“Investigator Veal also informed me that he had received BUTLER’s cell phone from Deputy Amad and that HDAO digital forensics team had completed a data extraction and download of the phone. Multiple Google searches related to Tesla had been made from BUTLER’s phone in the months leading up the crash. I noted multiple searches in May of 2026 indicating an apparent frustration with Tesla’s FSD mode, including the following searches: “Tesla fsd not aggressive enough 2026 model,” “Tesla fsd not [sic) aggressive enough 2026,” “FSD is not aggressive enough for city driving,” and “tesla fsd too timid.”‘
Tesla had claimed just after the crash that its internal data showed Butler had overridden the system’s speed control and pressed the accelerator completely, causing the vehicle to travel at an excessive rate of speed. Eventually, the car slammed into Avila’s house, killing her.
Butler has now been formally charged with Manslaughter, a felony.
Tesla shocked with its quarterly delivery report yesterday by reporting it delivered 480,126 vehicles in the second quarter of 2026, a 25 percent year-over-year jump that crushed Wall Street estimates of roughly 400,000–408,000 units. Production reached 451,758, with Model 3 and Model Y accounting for the vast majority.
The result ended two years of annual delivery declines and drew down inventory, signaling demand that outpaced earlier production.
Tesla bears had long warned that the expiration of the U.S. federal EV tax credit would hammer demand. Without the $7,500 incentive, they argued, American buyers would balk at higher effective prices, leading to a sharp slowdown.
Will Tesla thrive without the EV tax credit? Five reasons why they might
That narrative has not played out as predicted. While U.S. EV sales faced broader headwinds, Tesla’s global numbers held firm, underscoring the company’s ability to offset domestic pressure through other levers.
There are several plausible factors that explain Tesla’s strength during this quarter. Let’s take a look at them:
Rising Gas Prices
Rising gas prices provided a powerful tailwind, especially in the U.S.
Geopolitical tensions tied to the Iran conflict pushed fuel costs higher earlier in the year, amplifying the lifetime savings of electric vehicles. Even as oil prices later moderated, the psychological and financial impact lingered, encouraging fleet operators and private buyers to accelerate EV purchases. European sales rebounded sharply, helping drive the quarter’s outperformance.
Full Self-Driving Adoption
Advances in Full Self-Driving (FSD) supervised software also appear to have boosted appeal. Tesla expanded FSD availability in select European markets and continued refining the system.
No complaints from me because I finally got to enjoy this drive on FSD; I usually like to manually drive down this mountain https://t.co/RBFniRPSR0 pic.twitter.com/XQ5sOpN1Yg
— TESLARATI (@Teslarati) June 26, 2026
For tech-oriented buyers, the promise of future autonomy and enhanced driver-assistance features adds perceived value beyond the car itself. This differentiation helps Tesla stand out in a crowded market where competitors focus primarily on hardware and basic range.
Pricing Strategy, Affordable Configurations
Tesla’s offerings and its pricing strategy during Q2 further stimulated demand. Tesla introduced lower-cost versions of the Model 3 and Model Y, widening accessibility without sacrificing core margins.
These moves countered affordability concerns and attracted buyers who had been waiting on the sidelines. Combined with attractive financing and leasing options, the pricing strategy converted interest into actual orders more effectively than many analysts expected.
Broad European Recovery
Supported by government incentives, corporate fleet electrification, and easing political headwinds around CEO Elon Musk, Tesla was supplied additional momentum through stronger registration numbers throughout Europe.
Strong exports from the Shanghai Gigafactory and a production ramp at Giga Berlin ensured supply met this resurgent demand. Corporate buyers, in particular, accelerated transitions to EVs to meet sustainability targets, providing a steady volume base.
These elements created a virtuous cycle that delivered the strong deliveries report. While bears correctly flagged the loss of the U.S. tax credit as a risk, Tesla’s diversified playbook demonstrated that it could remain resilient against those headwinds. The Q2 beat suggests the company remains adept at navigating shifting market conditions, even as competition intensifies.
A Tesla Semi was involved in a fatal collision on U.S. Highway 50 in Dayton, Nevada, on Sunday, June 28, 2026, marking the first known fatal crash involving the electric Class 8 truck. The incident occurred around 7:20 a.m. at the intersection with Traditions Parkway, approximately 40 miles east of Reno and close to Tesla’s Gigafactory Nevada.
According to the Lyon County Sheriff’s Office and the Nevada State Police Highway Patrol, a semi-truck struck two passenger vehicles stopped at a traffic signal. The truck hit the vehicles from behind. Two people were pronounced dead at the scene, and a third person suffered life-threatening injuries and was flown to a hospital, Forbes reported.
Preliminary statements gathered at the scene by the Lyon County Sheriff’s Office suggested the truck driver may have fallen asleep at the wheel. However, the Nevada Highway Patrol, which is leading the investigation, stated that the official cause has not yet been determined.
Additional information is expected to be released early the following week. The truck was seized for evidence as part of the ongoing probe.
Responders at the scene included deputies from the Lyon County Sheriff’s Office, personnel from the Nevada Highway Patrol, Central Lyon County Fire Department, and the Nevada Department of Transportation. The crash led to the temporary closure of U.S. 50 in both directions.
The Tesla Semi is Tesla’s battery-electric heavy-duty truck, produced at the nearby Gigafactory in Nevada. Authorities initially described the vehicle as a semi-truck; its make was subsequently confirmed through reporting and scene identification; an interesting bit of information here, as the Semi is not yet available publicly and many do not know that Tesla builds electric trucks.
The investigation remains active, with no further official details on contributing factors or vehicle systems released as of early July 2026.
This incident highlights ongoing scrutiny of commercial vehicle safety on Nevada highways, particularly involving fatigue. Law enforcement continues to gather evidence and witness statements.
Texas man charged in fatal Tesla crash where he blamed Autopilot
Tesla’s strong Q2 deliveries: Four key drivers behind the surprise
