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Tesla Battery Day: A new form factor, the Roadrunner line, and what to expect

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Tesla’s Battery Day is coming tomorrow after the electric car maker’s 2020 Annual Shareholder Meeting. During the event, Tesla is expected to discuss the details of its next-generation battery cells, as well as their role in the world’s acceleration in sustainable energy. Actual details about Battery Day have been pretty scarce save for a few potential leaks, but that has not stopped the Tesla community from speculating about what the highly-anticipated event would involve. 

A concise summary of the current expectations for Battery Day was recently shared by Tesla Daily’s Rob Maurer, who compiled a list of topics that the electric car maker could cover during the event. Following then is a list of expectations about what Tesla could discuss tomorrow, as the company finally shows the world what it has been working on with regards to its battery technology. 

A New Cell Design 

Tesla has been teasing that it would be going into the production of battery cells. So far, leaks suggest that the company is about to adopt a larger form factor for its batteries, similar to how Tesla introduced the 2170 cells for the Model 3, which were larger than the 18650 cells used in the Model S and Model X. Leaks have pointed to Tesla’s new cells possibly adopting a 54×98 form factor, which has about 10x the volume of a 2170 cell. 

With larger form factors, the electrons and the ions travel larger distances as they move around in the cell, generating more friction and heat. This is a huge downside to larger cells, but Tesla’s tabless battery patent may hold the key to solving this issue. With a tabless battery cell design, the distance traveled by electrons and ions is largely reduced, limiting the disadvantages inherent among large cells. Such a design has several advantages, including better energy density and a more efficient manufacturing process. 

Battery Chemistry

Speculations are abounding that Tesla may discuss the amount of silicon that it is using in the anode of its next-generation cells. The more silicon that is used, the better the energy density. However, the utilization of silicon usually results in cracked anodes over time, reducing battery performance and life. Introducing more silicon into the anode is something that battery researchers have been attempting to accomplish for a while now, so it would be quite interesting if the electric car maker would announce some headway into its silicon use as well. 

Tesla may also discuss Maxwell’s technology and how it is being used for the company’s electric cars and energy storage devices. Maxwell has developed numerous innovations prior to its acquisition by Tesla, though the most relevant part of the company’s work in relation to the electric car maker is arguably its dry battery electrode tech. Considering that traditional lithium-ion batteries produce their electrodes in a wet slurry format (a rather lengthy process), dry electrode technology could vastly improve not only the energy density of Tesla’s cells, they could improve the production output of the batteries themselves as well. 

Cell-to-Pack Innovations

Tesla’s battery packs today feature cells that are packed into modules that are then packed into a battery pack. Back in the days of the original Roadster, battery modules were used as a means for the company to take out parts of the battery that may need to be replaced without taking out the entire pack. That was 12 years ago, however, and much has happened since then. Tesla has transitioned from a budding niche electric car maker to the manufacturer of the market’s best-selling EVs. 

As Elon Musk noted in the past, battery modules today are pretty much just an extra step, taking up weight without really serving a legitimate purpose. Musk then stated that the future is cell to pack without modules, suggesting that the company’s next-generation batteries will be using a cell-to-pack design. Such an innovation gives numerous benefits to Tesla, from lower production costs to possibly even better energy density. 

Battery Manufacturing and the Roadrunner Line

Elon Musk has always been pretty transparent about Tesla’s mission, which is to accelerate the advent of sustainable energy. Having enough batteries to enable such a transition is key to this goal. With this in mind, the potential innovations that Tesla will be discussing in Battery Day — a larger form factor that would allow the company to produce fewer cells to get the same amount of energy; a tabless cell design that could make production easier; dry electrode tech that could greatly increase the production capacity density of each battery; and a cell-to-pack design that should allow the production of batteries with less equipment at less cost — could ultimately pave the way for electric vehicles and energy storage products that are significantly better than the industry standard today. 

The Roadrunner project in Fremont is expected to be a central component of Tesla’s battery manufacturing plans, with attendees to the event being shown just how fast the company could produce its battery cells using its in-house production process. Elon Musk seems to be hyping the Roadrunner line recently on Twitter as well, when he made references to a game called “Factorio,” which happens to be a title focused on growing and maintaining advanced, efficient factories. 

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The Million-Mile Battery 

The million-mile battery has been heavily speculated for Battery Day. Tesla’s electric cars are already capable of lasting long despite heavy use, but with batteries and powertrains that could last a million miles, the company could create a generation of vehicles that are designed to be always operational for an extended period of time. Million-mile batteries are then crucial for Tesla’s plans to roll out a Robotaxi service, which involves vehicles traveling long distances every year. 

The Plaid Powertrain

With Tesla’s battery innovations in mind, speculations are high that the company would unveil its first vehicles that would carry its next-generation cells on Battery Day. Among Tesla’s ongoing projects, the Roadrunner cells seem to be a perfect match for cars like the Plaid Model S, Plaid Model X, and next-generation Roadster. All three vehicles have been confirmed by Elon Musk to feature the company’s upcoming “Plaid Powertrain,” which is something that has been heavily teased for some time now. Interestingly enough, updates on Tesla’s Plaid vehicles have been pretty scarce lately, making an announcement on Battery Day somewhat likely. 

Watch Rob Maurer’s full Tesla Battery Day predictions in the video below. 

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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Tesla Cybercab undergoes winter testing as Elon Musk reiterates production start date

CEO Elon Musk confirmed the timeline in a recent post on X, while Tesla’s official social media accounts separately revealed that Cybercab prototypes are now undergoing winter testing in Alaska.

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Credit: Tesla Robotaxi/X

Tesla has reiterated that production of its fully autonomous Cybercab is set to begin in April, even as the company continues expanding real-world testing of the vehicle. 

CEO Elon Musk confirmed the timeline in a recent post on X, while Tesla’s official social media accounts separately revealed that Cybercab prototypes are now undergoing winter testing in Alaska.

Musk confirms April Cybercab initial production

In a post on X, Musk reiterated that Cybercab production is scheduled to begin in April, reiterating his guidance about the vehicle’s manufacturing timeline. Around the same time, Tesla shared images showing the Cybercab undergoing cold-weather testing in Alaska. Interestingly enough, the Cybercab prototypes being tested in Alaska seemed to be equipped with snow tires. 

Winter testing in Alaska suggests Tesla is preparing the Cybercab for deployment across a wide range of climates in the United States. Cold temperatures, snow, ice, and reduced traction present some of the most demanding scenarios for autonomous systems, making Alaska a logical proving ground for a vehicle designed to operate without a human driver.

Taken together, Musk’s production update and Tesla’s testing post indicate that while the Cybercab is nearing the start of manufacturing, validation efforts are still actively ramping to ensure reliability in real-world environments.

What early Cybercab production might look like

Musk has previously cautioned that the start of Cybercab manufacturing will be slow, reflecting the challenges of launching an all-new vehicle platform. In a recent comment, Musk said initial production typically follows an S-curve, with early output constrained by how many new parts and processes are involved.

According to Musk, both Cybercab and Optimus fall into this category, as “almost everything is new.” As a result, early production rates are expected to be very deliberate before eventually accelerating rapidly as manufacturing processes mature.

“Initial production is always very slow and follows an S-curve. The speed of production ramp is inversely proportionate to how many new parts and steps there are. For Cybercab and Optimus, almost everything is new, so the early production rate will be agonizingly slow, but eventually end up being insanely fast,” Musk wrote in a post on X.

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Tesla to increase Full Self-Driving subscription price: here’s when

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Tesla will increase its Full Self-Driving subscription price, meaning it will eventually be more than the current $99 per month price tag it has right now.

Already stating that the ability to purchase the suite outright will be removed, Tesla CEO Elon Musk said earlier this week that the Full Self-Driving subscription price would increase when its capabilities improve:

“I should also mention that the $99/month for supervised FSD will rise as FSD’s capabilities improve. The massive value jump is when you can be on your phone or sleeping for the entire ride (unsupervised FSD).”

This was an expected change, especially as Tesla has been hinting for some time that it is approaching a feature-complete version of Full Self-Driving that will no longer require driver supervision. However, with the increase, some are concerned that they may be priced out.

$99 per month is already a tough ask for some. While Full Self-Driving is definitely worth it just due to the capabilities, not every driver is ready to add potentially 50 percent to their car payment each month to have it.

While Tesla has not revealed any target price for FSD, it does seem that it will go up to at least $150.

Additionally, the ability to purchase the suite outright is also being eliminated on February 14, which gives owners another reason to be slightly concerned about whether they will be able to afford to continue paying for Full Self-Driving in any capacity.

Some owners have requested a tiered program, which would allow people to pay for the capabilities they want at a discounted price.

Unsupervised FSD would be the most expensive, and although the company started removing Autopilot from some vehicles, it seems a Supervised FSD suite would still attract people to pay between $49 and $99 per month, as it is very useful.

Tesla will likely release pricing for the Unsupervised suite when it is available, but price increases could still come to the Supervised version as things improve.

This is not the first time Musk has hinted that the price would change with capability improvements, either. He’s been saying it for some time. In 2020, he even said the value of FSD would “probably be somewhere in excess of $100,000.”

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Tesla starts removing outright Full Self-Driving purchase option at time of order

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(Credit: Tesla)

Tesla has chosen to axe the ability to purchase Full Self-Driving outright from a select group of cars just days after CEO Elon Musk announced the company had plans to eliminate that option in February.

The company is making a clear-cut stand that it will fully transition away from the ability to purchase the Full Self-Driving suite outright, a move that has brought differing opinions throughout the Tesla community.

Earlier this week, the company also announced that it will no longer allow buyers to purchase Full Self-Driving outright when ordering a pre-owned vehicle from inventory. Instead, that will be available for $99 per month, the same price that it costs for everyone else.

The ability to buy the suite for $8,000 for a one-time fee at the time of order has been removed:

This is a major move because it is the first time Tesla is eliminating the ability to purchase FSD outright for one flat fee to any of its vehicles, at least at the time of purchase.

It is trying to phase out the outright purchase option as much as it can, preparing people for the subscription-based service it will exclusively offer starting on February 14.

In less than a month, it won’t be available on any vehicle, which has truly driven some serious conversation from Tesla owners throughout the community.

There’s a conflict, because many believe that they will now lose the ability to buy FSD and not pay for it monthly, which is an attractive offer. However, others believe, despite paying $8,000 for FSD, that they will have to pay more money on top of that cost to get the unsupervised suite.

Additionally, CEO Elon Musk said that the FSD suite’s subscription price would increase over time as capabilities increase, which is understandable, but is also quite a conflict for those who spent thousands to have what was once promised to them, and now they may have to pay even more money.

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