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Auto experts reveal why Tesla’s batteries hold a comfortable lead in range

Tesla's 2170 battery cells. (Credit: Tesla)

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One of the reasons why the narrative of the “Tesla Killer” has effectively died is due to the pervading lead that Tesla holds over the competition in terms of range. Amidst the long-predicted entrance of competing vehicles from established automakers including Audi, Jaguar, and Porsche, Tesla’s vehicles have proven to be vastly superior in range, as evidenced by the Model S Long Range, which can last 370 miles in between charges. 

Take Tesla’s very first car, the original Tesla Roadster. The vehicle featured Tesla’s efforts at creating a desirable all-electric sports car, and it showed in the Roadster’s robust 245-mile range. There weren’t even Superchargers when the Roadster was released, but the car proved that EVs could comfortably go beyond the 200-mile mark, and then some more. Interestingly, even modern EVs from veteran carmakers are finding it hard to match the Roadster’s 245-mile EPA range. The Audi e-tron, for example, just has 204 miles of range per charge, while the award-winning I-PACE has an EPA rating of 234 miles per charge. 

This, according to veteran auto experts Sandy Munro and Mark Ellis of Munro & Associates, has a lot to do with Tesla’s all-electric platform and the company’s proprietary battery tech. Tesla is only 16 years old, and thus, it only has a fraction of the experience that its rivals in the auto market has. Yet in the EV segment, Tesla is among the veterans, having worked solely on electric cars since Day One. 

All-Electric

As such, vehicles that Tesla releases such as the Model S, Model X, and Model 3, are designed as EVs from the get-go. In contrast, carmakers such as Mercedes-Benz and Audi opted to convert existing platforms for EV production. This reduces costs, but it is a double-edged strategy in the EV segment, which is starting to gain serious ground in several key markets. “If you’re designing something radically different, or if you want to have something that’s going to be a world-beater in the marketplace, that parts bin is the worst thing imaginable,” Munro said.

This could be seen in the difference between the Porsche Taycan and a vehicle such as the Mercedes-Benz EQC. Porsche opted to design the Taycan from a clean sheet, and the result was an all-electric sports car that can attack the track just as aggressively as the next 911. It even has a frunk like a Tesla, albeit smaller. Mercedes, on the other hand, opted to base the EQC on its existing GLC platform, and the result is an EV that still has echoes of its internal combustion roots. Between the two vehicles, it is easy to see which carmaker put more effort, and it shows. Today, it appears that the non-Tesla EV community is far more excited about the Taycan than they are for the EQC. 

Mark Ellis, a senior master of lean design and battery consultant, notes that this is a key advantage that is inherent in Tesla. “One of Elon Musk’s big advantages is, basically, that the vehicle is designed to be an electric car. Musk designed every aspect of this car to be as efficient as possible,” he said

The Secret Sauce

Apart from their all-electric design, Tesla’s secret sauce for its vehicles lies in their batteries, from the design of the pack to the chemistry of the cells themselves. Comparing the Model 3’s battery pack to those found in other EVs such as the Chevrolet Bolt EV, Nissan Leaf, Jaguar I-PACE, and BMW i3, Ellis stated that Tesla’s battery pack is superior, especially with regards to the placement of battery cells in relation to the current collectors. “It’s the best design of any battery pack I’ve seen so far,” he said. 

But this is not all. Ellis added that Tesla’s cylindrical cells have inherent advantages compared to the prismatic or pouch cells used by the competition. Prismatic cells, for one, expand and contract as they charge and discharge, which means that manufacturers using them have to design their battery packs with the necessary parts to handle the expansion and contraction process of the cells. These add unnecessary weight to a battery, which Tesla’s packs don’t have to deal with. 

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Ultimately, Ellis explained that Tesla’s battery cells simply have a higher energy density than those utilized by its competition. Tesla was able to achieve this because its batteries have superior chemistry, the consultant said. Part of the reason behind this is the fact that Tesla as a company does not really stop innovating. Tesla’s Automotive President Jerome Guillen hinted at this in a previous interview, when he said that the company’s batteries are never frozen since they are always in a state of improvement. “We are improving the design of the cell. The design of the cell is not frozen. It evolves, and we have a nice roadmap of technology improvements for the coming years,” Guillen said.

Range is something that is one of the most important factors consumers consider when purchasing an electric car. With the number of EV charging stations not yet on par with the number of gas stations on the road, it is pertinent for customers for many car buyers to acquire a vehicle that can go the distance. Tesla’s long-range vehicles, together with the company’s Supercharger Network, are a perfect fit for these types of customers.

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

Why automakers keep turning down Elon Musk’s Tesla Full Self-Driving offer

Elon Musk confirms no automaker has ever accepted Tesla’s offer to license Full Self-Driving software.

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Elon Musk gave a brief answer on X Monday that confirmed that Tesla’s standing offer to license Full Self-Driving to other automakers still has zero takers. Sawyer Merritt wrote that “Tesla has for years openly invited other automakers to license FSD. None of them have accepted,” responding to a prediction from Boom Supersonic founder Blake Scholl that Tesla would eventually open FSD the way it opened its Supercharger network to rival brands. Musk’s reply to Merritt was one word: “Exactly.”

It is not the first time Musk has made this point. He said something similar in November, when he called legacy automakers reluctance to adopt FSD “crazy,” and Tesla has floated the offer publicly since at least 2021. Scholl’s prediction touches on something real. Once NACS became the de facto charging standard, adoption from Ford, GM, Rivian and others followed within about a year. FSD licensing was supposed to work the same way once Tesla built enough of a lead that switching made sense for everyone.

The case for licensing now is stronger than it was two years ago. Waymo and Zoox are logging hundreds of thousands of unsupervised autonomous miles, along with Tesla’s own Robotaxi fleet. Every automaker still selling driver assist systems that lag FSD has given the robotaxi conversation to Tesla, Waymo and Zoox by default. Licensing FSD would let a GM or a Ford compete on the same field without spending a decade and billions of dollars building a stack from scratch, the same argument Tesla made when it opened the Supercharger network to bring more EVs onto its chargers.

But FSD is not a connector standard. As one reply to Musk’s post pointed out, licensing FSD is not a software license the way NACS was a plug spec. It requires adopting Tesla’s eight camera layout and its onboard compute architecture, meaning a licensee’s cars would effectively become Tesla hardware wearing someone else’s badge. That is the visible obstacle. The less visible one is data. A licensed FSD stack would report back the same telemetry Tesla collects from its own fleet, giving Tesla a continuous read on how a competitor’s cars are actually driven, where they struggle, and how often drivers intervene. For an automaker trying to build its own autonomy program, or simply trying to keep its build quality and safety record private, handing Tesla that visibility could be a bigger cost than the hardware bill. It is the reason the Supercharger comparison only goes so far. Opening a charging plug cost Tesla very little. Opening FSD would cost a rival something it cannot get back.

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Elon Musk

Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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