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Tesla’s battery strategy will be key to Cybertruck and Semi’s market disruption
Elon Musk has remarked that Tesla has arguably the most exciting product roadmap of any company today. With vehicles like the Semi and the Cybertruck coming in the pipeline, this statement rings true. But things will not be as easy as simply setting up production lines for the upcoming vehicles. For Tesla to properly ramp the Semi, for example, the company would have to make sure that it can get enough cells for the vehicle first.
Producing electric cars is no easy task, and a lot of the challenges in EV making are connected in one way or another to vehicles’ batteries. This is something that is being learned by veteran carmakers like Jaguar today, as inadequate supply from battery companies like LG Chem has resulted in a halt of production for premium EVs like the I-PACE. Tesla is certainly aware of the battery supply challenges that EV makers face. This is one of the reasons why Gigafactory Nevada was constructed.
Giga Nevada was built to support the company’s Model 3 ramp. Designed to manufacture the 2170 cells of the Model 3 with battery partner Panasonic, the massive facility forms the backbone of Tesla’s first foray into the mass market. But the story lies far beyond the Model 3 today. Tesla has an even higher-volume vehicle coming, the Model Y. The Cybertruck will likely sell in large volumes too, provided that the market embraces it. Just like the all-electric pickup, the Semi might see sufficient demand from the trucking market once it’s released as well, considering the cost benefits that the vehicle offers.
Tesla is in a constant state of change, and this cannot be represented better than the company’s batteries. President of Automotive Jerome Guillen has noted that Tesla’s batteries are never static since they’re always being improved. Today, it is becoming more and more evident that Tesla’s batteries are among the best in the industry, particularly when it comes to energy density. Coupled with its vertically-integrated software, Tesla’s batteries can give vehicles impressive range even if they are not too large.
The Model 3, for example, can squeeze out over 320 miles of range from a 75 kWh battery, and the Model S Long Range Plus can get 390 miles from a 100 kWh pack. This matters a lot, and it shows just how far ahead the company is when it comes to its batteries and their energy density. And this, ultimately, will likely help the company secure enough battery cells to support the ramp of its upcoming EVs, including the Semi and the Cybertruck, both of which are large vehicles that would usually require a massive pack to hit their target range.
Tesla lists the Semi with a range of 300 to 500 miles. The company never announced the size of the Semi’s battery pack, but considering that the vehicle is a Class 8 truck that can accelerate from 0-60 mph in 20 seconds with a full load, speculations for the vehicle’s battery from the EV community included estimates that were as high as 1 MWh. The same concept applies to the Cybertruck. The vehicle is very heavy, and it is expected to have over 500 miles of range. To get this range, a large battery pack would usually be required.
But with Tesla’s constant innovations on its batteries, this does not necessarily have to be the case. Considering that Tesla is closing in on 400 miles per charge on a 100 kWh pack with the Model S, there is a good chance that its next vehicles like the Cybertruck and Semi will be equipped with fewer, but more energy-dense cells than initially expected. Tesla has pretty much developed the skill of drawing out as much range as possible from every cell in an EV, so it’s not too farfetched to infer that the company will be very efficient with the batteries of its upcoming vehicles.
More energy-dense batteries will be key to lowering production costs as well. Tesla may be drastically reducing its battery costs, but the packs themselves still comprise a huge portion of each of its vehicles’ prices. If Tesla can use slightly smaller packs that are still capable of providing optimum range, Tesla can make sure that its EVs like the Semi and the Cybertruck will be as competitive as possible when they enter the market.
The Tesla Semi and the Cybertruck are competing in the trucking and pickup market, two very lucrative segments in the automotive industry. Interestingly, both segments are also ripe for disruption, with most veterans such as Freightliner and the Ford F-150 sticking to tried and tested strategies to thrive today. Tesla needs a key to ensure that it can have a fighting chance when it enters the trucking and pickup segment with the Semi and Cybertruck. If challenges faced by electric car makers today are any indication, it appears that batteries and their energy density will be the difference-maker. Fortunately, these just happen to be two things that Tesla has been obsessively pursuing since the company was founded less than 17 years ago.
Tesla Cybertruck Lead Engineer Wes Morrill revealed the company has made several changes to the all-electric pickup, which he calls a “living thing, constantly evolving and improving.”
Cybertruck is manufactured at Tesla’s Gigafactory Texas just outside of Austin, and over the past few years, Tesla has continued to make small changes to the pickup to improve everything from cost, reliability, serviceablility, and manufacturability.
“The finish line isn’t getting to production. A product is a living thing, constantly evolving and improving,” Morrill added.
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Some of those changes are yet to be revealed, but perhaps the most notable one was the change Tesla made to the aero shield that sits underneath the truck. In the past, it was aluminum, but now the Cybertruck is using a self-reinforcing polypropylene.
Morrill said that the polypropylene is “stretched into fibers and then laminated into the form,” and is much more durable, much lighter, and significantly cheaper than aluminum when it is manufactured this way.
It also enabled some improvements in the geometry of the Cybertruck, improving the manufacturing around the bolts and edges, in addition to minor form changes. These all benefitted the Cybertruck in more ways than one: specifically with durability and improved drag.
I was surprised by how interested people were to find out we made a relatively benign change to the Cybertruck aero shield, a part of the car most people never even see. So I’ll share some more details.
Here are two photos, the left is one of the latest trucks off the… pic.twitter.com/F5cZo2CZKf
— Wes (@wmorrill3) September 7, 2026
Typically, Teslas are not necessarily identified by model year because these changes are fluid and occur when the company sees fit to implement them. It is not like other automotive companies, which usually make sweeping manufacturing changes when building a new model year.
Instead, Teslas are recognized by their “generation” or “era.” For example, those with a newer Model Y might refer to their car as a “Juniper.” This is the same with Model 3, as many refer to the new body style as the “Highland.”
Tesla’s manufacturing changes are proof of the company’s constant need to improve its products and move things forward with its vehicles. There is no need to drag one’s feet and wait until next year if the product can be made better right now, and that’s precisely what Tesla did with the Cybertruck.
Elon Musk
Tesla Cybercabs narrowly miss deadly Amazon cargo plane crash
An Amazon cargo plane crash near Miami’s airport stopped feet from dozens of Tesla Cybercabs.
An Amazon Prime Air Boeing 767 cargo jet overran the runway at Miami International Airport on Sunday afternoon, killing five people and injuring five more. The jet, operated by North Carolina based carrier 21 Air as Flight 7598, touched down around 2 p.m. after arriving from San Juan, Puerto Rico, then crossed the airport perimeter, plowed across NW 67th Avenue and struck multiple vehicles before catching fire, according to the Associated Press.
Photos and video from the scene show the aircraft’s nose stopped within meters of a fenced staging lot holding dozens of gold painted Tesla Cybercabs, the steering wheel free robotaxi Tesla began putting on public roads in Austin last week. Miami-Dade Fire Rescue has confirmed the plane struck “multiple vehicles” but has not said whether any Cybercabs were among them, and neither Tesla nor airport officials have addressed the fleet directly.
The Cybercabs had not yet entered commercial service in Miami. Tesla’s existing Robotaxi operation there runs on modified Model Y vehicles and has been unsupervised since Ashok Elluswamy confirmed the detail on X in July.
Footage of the plane crash from earlier today | #ONLYinDADE pic.twitter.com/iGoOtnd6cD
— ONLY in DADE (@ONLYinDADE) September 6, 2026
Elon Musk offered the briefest of reactions. Replying to a Zero Hedge post about the Cybercabs sitting so close to the wreckage, he wrote a single word: “Weird.” He has not commented further, and Tesla has not issued a statement.
The timing puts Tesla’s newest vehicle near an unrelated but highly visible tragedy just days after its Austin debut, a launch that had already drawn scrutiny from federal regulators. The National Highway Traffic Safety Administration opened an audit how Tesla certified the Cybercab as compliant with federal vehicle safety standards, a process Teslarati covered after the vehicle’s September 3 launch event. That inquiry concerns the car’s lack of a steering wheel and pedals, not the Miami crash.
Investigators from the FAA and NTSB are focused on the plane, not the parking lot beside it. Flight data reviewed by outlets including Simple Flying show the 767 touched down around 170 knots, well above the 135 to 140 knot range typical for the aircraft, though investigators have not determined a cause. Amazon said it is working with authorities and that its priority is the safety of everyone affected.
Whether any Cybercabs were damaged, and what Tesla plans for the fleet parked near one of the country’s busiest airports, remain open questions.
Tesla has reached a notable benchmark in its autonomous driving program after its Robotaxi fleet surpassed one million miles of unsupervised operation. The company made the announcement during its Cybercab event in Austin on September 3.
Tesla Vice President of AI Ashok Elluswamy told attendees he was happy to report the fleet had achieved one million miles of unsupervised Robotaxi operation as a testament to safety.
The new total marked a sharp increase from the 380,000 unsupervised miles Tesla disclosed during its second-quarter 2026 earnings update in late July.
In roughly six weeks, the company added about 620,000 miles. That acceleration followed Tesla’s decision to remove in-vehicle safety monitors from most of its operations outside the San Francisco Bay Area.
Credit: Tesla
Tesla first launched Robotaxi service in Austin in June 2025 with safety drivers present. It later began fully unsupervised rides and expanded into Dallas, Houston, Miami, Orlando, and Tampa. The San Francisco Bay Area remains the exception, where a safety monitor still rides in the vehicle under California permitting rules.
The company has not released a city-by-city breakdown of the one million unsupervised miles.
The milestone arrived as Tesla began offering public Cybercab rides in Austin. The purpose-built vehicle has no steering wheel or pedals and is designed only for autonomous ride-hailing. Production versions joined the existing fleet of modified Tesla vehicles already operating in the service.
Tesla’s unsupervised mileage is growing at a double-digit weekly rate according to earlier company comments, yet its fleet size remains modest compared with established competitors. Waymo has accumulated more than 200 million fully autonomous rider-only miles. Tesla has described its own unsupervised operations as having recorded zero notable incidents in the period leading up to the July update.
The one-million-mile figure reflects Tesla’s shift from supervised testing to broader driverless service in multiple states. It also highlights the company’s strategy of using both existing Model Y vehicles and the new Cybercab to scale its network.
Credit: Tesla
Whether the rapid recent growth continues will depend on further city expansions, regulatory approvals, and the performance of the purpose-built Cybercab in everyday paid rides. Tesla has not specified how many of the latest miles involved the new vehicle versus the rest of the fleet.
The announcement underscores Tesla’s progress toward a larger robotaxi network while illustrating the remaining gap in total autonomous experience relative to longer-operating rivals.
Tesla Cybertruck engineer reveals new changes in ‘constantly evolving’ pickup
Tesla Cybercabs narrowly miss deadly Amazon cargo plane crash
