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Tesla’s approach to battery technology keeps it ahead in the EV industry
Tesla’s dominance in the growing electric vehicle (EV) industry is largely attributed to its unique approach to its battery technology. The engineering behind the all-electric car maker’s cylindrical cells speaks for itself in terms of the performance and range achieved, but in a recent interview with a battery technology researcher, a few things detailed about Tesla’s batteries stood out in particular.
Ravindra Kempaiah is a Ph.D. scholar at the University of Illinois Chicago focusing on advanced battery materials for his thesis. In his interview with Tesla owner and host of All Things EV, Sean Mitchell, Kempaiah explained lithium-ion technology in EVs and the primary issues faced in their development. Overall, the biggest challenge is balancing the three main components in battery production: energy density, cost, and cycle life. Increasing one area will significantly impact the other, and the ideal equation is always being sought after. For example, if you increase energy density for higher range and lower cost, the cycle life takes a major hit. If you increase density and life cycle, the battery alone can cost as much as $100k, as described by Kempaiah.
“We always want more range. We always want higher cycle life. We want our batteries to last 15-20 years and the car to go 500 miles, but this is a problem every battery scientist has faced for the last 30 years,” Kempaiah commented in the interview.
Tesla deals with the same balancing act as other battery-electric car makers; however, there are key factors which seem to have kept the company ahead in the industry.
First, Tesla’s choice of cylindrical cells sets it apart from every other electric vehicle on the market. This provides several advantages that drive performance, flexibility, and cost control. Notably, Rivian is also using cylindrical cells, although their vehicles are not yet under production.
Out of the three types of cells available (cylindrical, prismatic, and pouch cells), cylindrical is the most cost-effective to produce. Namely, the cost per kWh is lower in cylindrical cells versus other types. The metallic jacket around the 18650 and 2170 cylindrical cells used in the Tesla Model S/X and Model 3, respectively, acts as scaffolding and provides structural rigidity to the battery. Additionally, in high powered situations, current draw and distribution of power is over the entirety of the battery pack instead of concentrated in a certain section, according to Kempaiah.
Second, Tesla uses a liquid-cooled thermal management system to manage battery temperatures whereas other automakers take a more economical air cooling approach. By adjusting the temperature of the battery pack, Tesla is able to ensure that cells are operating in their most efficient and optimal states, thereby maximizing battery longevity as well as performance. While reducing cost is an important factor in accelerating the growth of the electric vehicle market, Tesla’s investment in thermal management technology provides an upside for owners who may be looking for longevity and long-term affordability of their cars.
Third, Tesla has actively sought to limit the amount of cobalt it uses in its batteries and already uses less of the element than other companies in the Model 3 batteries. The scarcity of cobalt and its mining sources have subjected it to socioeconomic situations that are more than problematic in the United States, i.e., child labor and similar abuses are widespread in its sourcing. With this in mind, Tesla has been working on the question, “Is cobalt really needed?”
Cobalt is used as a cathode in battery technology, and out of all cathode materials available, it has the highest cost both fiscally and politically. Current consensus on battery technology says that without cobalt, the structural integrity and cycle life in batteries is compromised, as described in the interview. However, some recent scientific literature was cited by Kempaiah that indicated higher nickel content limited the impact of cobalt on batteries, possibly removing the need to use it at all. Nickel is more widely available across the globe, which keeps its cost down and mitigates the socioeconomic impacts often associated with resource mining operations. Overall, the discussion between Mitchell and Kempaiah indicated that Tesla can probably go cobalt-free soon, making it less vulnerable to the cobalt industry.
Finally, Tesla takes great care to educate its customers about proper battery maintenance, especially with regard to the negative impact of bad charging habits. Specifically, keeping an electric car battery charged at 100% for long periods degrades the battery very quickly, while keeping charging states within an optimal range will give it a long life. Tesla makes it a point to communicate to customers the importance of battery health on their overall ownership experience and value of their purchase.
When asked for his opinion by Mitchell, Kempaiah attributed the lack of education by other brands as a disconnect between engineering teams and marketing teams. While battery “best practices” are provided to EV customers by all manufacturers, the importance of communicating the true impact of bad charging habits may not be emphasized enough to be included as prominently as it should.
In summary, Tesla is constantly developing the technology in its vehicles, and its particular attention to its batteries looks to have given the company a significant advantage over its competitors. Perhaps other automakers will take a few tips from Tesla in the future, even if it’s as limited as improving communications with customers.
Watch Sean Mitchell’s full interview with Ravindra Kempaiah below:
News
Tesla Robotaxi has already surpassed Waymo in this key metric
Tesla Robotaxi has already overtaken Waymo in Austin in one key metric, but there’s still more work to do.
Tesla Robotaxi has already surpassed Waymo in one extremely important key metric: size of service area.
Tesla just expanded its service area in Austin on Monday morning, pushing the boundaries of its Robotaxi fleet in an interesting fashion with new capabilities to the north. Yes, we know what it looks like:
🚨 Tesla’s new Robotaxi geofence is…
Finish the sentence 🥸 pic.twitter.com/3bjhMqsRm5
— TESLARATI (@Teslarati) July 14, 2025
The expansion doubled Tesla Robotaxi’s potential travel locations, which now include the University of Texas at Austin, a school with over 53,000 students.
The doubling of the service area by Tesla has already made its travel area larger than Waymo’s, which launched driverless rides in October 2024. It became available to the public in March 2025.
According to Grok, the AI agent on X, Tesla Robotaxi’s current service area spans 42 square miles, which is five square miles larger than Waymo’s service area of 37 square miles.
Tesla Robotaxi (red) vs. Waymo geofence in Austin.
Much can be said about the shape… but the Robotaxi area is now ~3.9 mi² (10 km²) larger than Waymo’s!! pic.twitter.com/dVfh2ODxJC
— Robin (@xdNiBoR) July 14, 2025
The service area is one of the most important metrics in determining how much progress a self-driving ride-hailing service is making. Safety is the priority of any company operating a ride-hailing network, especially ones that are making it a point to use autonomy to deploy it.
However, these companies are essentially racing for a larger piece of the city or cities they are in. Waymo has expanded to several different regions around the United States, including Arizona and Los Angeles.
Tesla is attempting to do the same in the coming months as it has already filed paperwork in both California and Arizona to deploy its Robotaxi fleet in states across the U.S.
As the platform continues to show more prowess and accuracy in its operation, Tesla will begin to expand to new areas, eventually aiming for a global rollout of its self-driving service.
News
Tesla Megapacks arrive for massive battery replacing coal plant
Tesla Megapacks have started arriving on-site to the Stanwell Battery Project, just as Queensland prepares to wind down the Stanwell coal plant.
The first of over 300 Tesla Megapacks have arrived to the site of a massive battery energy storage system (BESS) being built in Australia, dubbed the Stanwell Battery Project after a coal plant it’s set to replace.
In a press release last week, the Stanwell Battery Project announced that the first Tesla Megapack 2XL units had arrived to the site, which is located outside of Rockhampton in Queensland, Australia. The project will eventually feature 324 Megapack units, set to arrive in the coming months, in order to support the 300MW/1,200MWh battery project.
“The Stanwell Battery is part of the diversification of our portfolio, to include cleaner and more flexible energy solutions,” said Angie Zahra, Stanwell Central Generation General Manager. “It is just one part of the 800 MW of battery energy storage capacity we have in our pipeline.
“Capable of discharging 300 MW of energy for up to four hours (1,200 MWh), our mega battery will be one of the largest in Queensland.”
Credit: Stanwell
Did you know Tesla’s Lathrop facility churns out a Megapack every 68 minutes? That’s enough energy to power 3,600 homes for an hour per unit! ⚡️ pic.twitter.com/bG6fpHkB9O
— TESLARATI (@Teslarati) June 11, 2025
READ MORE ON TESLA MEGAPACKS: Tesla Lathrop Megafactory celebrates massive Megapack battery milestone
The state is working with government-owned company Yurika to facilitate construction, and the process is expected to create roughly 80 jobs. The project is expected to come fully online in May 2027, with initial commissioning of the Megapacks aiming for November 2025.
The Stanwell Battery is set to replace the nearby Stanwell coal generation plant, which the government is planning to wind down starting in 2026 as part of efforts to reach an 80 percent renewable energy generation ratio by 2035. Meanwhile, the government is also set to begin winding down the Tarong and Callide coal plants, while several other Megapack projects are being built or coming online. o ya
Tesla currently has two Megapack production facilities, located in Lathrop, California, in the U.S. and another that came online earlier this year in Shanghai, China. The Shanghai Megafactory shipped its first units to Australia in March, while both factories are expected to be capable of producing 10,000 Megapack units per year upon reaching volume production.
News
The Tesla Diner is basically finished—here’s what it looks like
The company first broke ground on the Diner, Drive-in, and Supercharger location in September 2023. Now, it has served one of its first internal customers.
Tesla has finally completed the construction of its highly anticipated Diner, Drive-in, and Supercharger in Los Angeles, and recent photos of the interior’s “retro-futuristic” style are making their way around the internet.
X user Brad Goldberg shared photos from the Tesla Diner site last Tuesday, depicting some of the Supercharger stalls, indoor and outdoor seating areas, multiple neon lights, and even an Optimus robot. Goldberg also noted that there had been a “flurry of activity on site” while he was snapping the photos last week, suggesting that the restaurant location could be getting close to opening.
The Tesla Diner also served one of its first internal customers in the past few days, as Elon Musk posted on X on early Monday morning that he had just finished up eating a meal at the site:
I just had dinner at the retro-futuristic Tesla diner and Supercharger.
Team did great work making it one of the coolest spots in LA!
The photos also show that the site is pretty much done, with some of them even showing vehicles charging at the charging stalls.
You can see some of the latest photos of the Tesla Diner below.
Credit: BradGoldbergMD | X
Credit: BradGoldbergMD | X
Credit: BradGoldbergMD | X
Credit: BradGoldbergMD | X
Credit: TeslaKing420 | X
Credit: TeslaKing420 | X
Credit: Brad Goldberg (via Sawyer Merritt on X)
Credit: Brad Goldberg (via Sawyer Merritt on X)
Credit: Brad Goldberg (via Sawyer Merritt on X)
Credit: Brad Goldberg (via Sawyer Merritt on X)
Credit: Brad Goldberg (via Sawyer Merritt on X)
READ MORE ON TESLA’S LA DINER: Tesla readies Drive-In Diner Supercharger for launch with app inclusion
When will the Tesla Diner open to external customers?
While it’s still not open to external customers yet, the news again suggests that the company could be close to an official opening date. Tesla first broke ground on the Diner in September 2023, after receiving a wave of building permit approvals throughout that year. Teslarati also covered much of the construction progress throughout last year, including when crews installed the first and second drive-in screens.
Located at 7001 West Santa Monica Boulevard, the idea was first discussed in 2018 by Musk and a few others on Twitter, featuring 1950s rock and roll, waiters on roller skates, and drive-in movie theater screens playing clips from some of history’s best movies. Notably, the photos of the front doors also show that the site will be open 24 hours a day, 7 days a week, whenever it does end up opening.
Tesla’s progress on Supercharger with diner, drive-in seen in aerial footage
Tesla Robotaxi has already surpassed Waymo in this key metric
Tesla Megapacks arrive for massive battery replacing coal plant
The Tesla Diner is basically finished—here’s what it looks like
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