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

(Credit: Tesla)

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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. 

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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. 

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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. 

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. 

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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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ARK’s SpaceX IPO Guide makes a compelling case on why $1.75T may not be the ceiling

ARK Invest breaks down six reasons SpaceX’s $1.75 trillion IPO valuation may be justified.

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ARK Invest, which holds SpaceX as its largest Venture Fund position at 17% of net assets, has published a detailed investor guide to why a SpaceX IPO may be grounded in a $1.75 trillion target valuation.

The financial case starts with Starlink, SpaceX’s satellite internet constellation, which has surpassed 10 million active subscribers globally as of early 2026, with 2026 revenue projected to exceed $20 billion. ARK’s research puts the total satellite connectivity market opportunity at roughly $160 billion annually at scale, and Starlink is adding customers faster than any telecom network in history. That growth alone would justify a substantial valuation.

Additionally,  ARK notes that SpaceX has reduced the cost per kilogram to orbit from roughly $15,600 in 2008 to under $1,000 today through reusable Falcon 9 hardware. A fully operational Starship targeting sub-$100 per kilogram would represent a significant cost decline and open markets that do not currently exist. SpaceX executed a staggering 165 missions in 2025 and now accounts for approximately 85% of all global orbital launches. That infrastructure position took decades to build and would be nearly impossible to replicate at comparable cost.

SpaceX officially acquires xAI, merging rockets with AI expertise

The February 2026 merger with xAI added a layer to the valuation that straightforward financial models struggle to capture. ARK argues that at sub-$100 launch costs, orbital data centers could deliver compute roughly 25% cheaper than ground-based alternatives, without power grid delays, permitting friction, or land constraints. Musk has stated a goal of deploying 100 gigawatts of AI computing capacity per year from orbit.

The $1.75 trillion figure itself is not a conventional earnings multiple. At roughly 95x trailing revenue, it prices in Starlink’s adoption curve, Starship’s cost trajectory, and the orbital compute thesis together. The public S-1 prospectus, due at least 15 days before the June roadshow, will give investors their first complete look at the financials to test those assumptions. ARK’s position is that the track record earns the benefit of the doubt. Fully reusable rockets were considered unrealistic for years. Starlink was considered financially unviable. Both happened on timelines that surprised skeptics.

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Elon Musk

Ford CEO Farley says Tesla is not who to look at for EV expertise

Interestingly, Farley has been one of the most hellbent CEOs in terms of a legacy automaker standpoint to push the EV effort. It did not go according to plan, as Ford took a $19.5 billion charge and retreated from its EV push in late 2025.

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Ford CEO Jim Farley said in a recent podcast interview that Tesla is not who Americans should look at to beat Chinese carmakers.

The comments have sparked quite a bit of outrage from Tesla fans on X, the social media platform owned by Elon Musk.

Farley said that Chinese automakers are better examples of how to beat competitors. He said (via the Rapid Response Podcast):

“If you’re an American and you want us to beat the Chinese in the car business, you’re all going to want to pay attention, not necessarily to Tesla. Nothing against Tesla—they’ve been doing great—but they really don’t have an updated vehicle. The best in the business for us, cost-wise and competition-wise, supply chain, manufacturing expertise, and the I.P. in the vehicle, was really BYD. In this next cycle of EV customers in the U.S., they want pickups and utilities and all these different body styles. But they want them at $30,000, not $50,000. Like the first inning, they want them affordably.”

Despite Farley’s synopsis, it is worth mentioning that Tesla had the best-selling passenger vehicle in the world last year, and in China in March, as the Model Y continued its global dominance over other vehicles.

Musk responded to Farley’s comments by stating:

“This is before Supervised FSD is approved in China. Limiting factor is production output in Shanghai.”

Interestingly, Farley has been one of the most hellbent CEOs in terms of a legacy automaker standpoint to push the EV effort. It did not go according to plan, as Ford took a $19.5 billion charge and retreated from its EV push in late 2025.

Ford cancels all-electric F-150 Lightning, announces $19.5 billion in charges

Instead, Ford is “doubling down on its affordable” EVs and said it would pivot from its previous plans.

Reaction from Tesla fans was pretty much how you would expect. Many said they have lost a lot of respect for Farley after his comments; others believe he is the last CEO anyone should be taking advice on EVs from.

Nevertheless, Farley’s plans are bold and brash; many consider Tesla the most ideal company to replicate EV efforts from. It will be interesting to see if Ford can rebound from this big adjustment, and hopefully, Farley’s plans to replicate efforts from BYD work out the way he hopes.

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Elon Musk

SpaceX wins its first MARS contract but it comes with a catch

NASA awarded SpaceX a $175 million Mars rover contract while the White House proposes cutting the mission.

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NASA just signed a $175.7 million contract with SpaceX to launch a Mars rover that the White House is simultaneously trying to defund. The contract, awarded on April 16, 2026, tasks SpaceX’s Falcon Heavy with launching the European Space Agency’s (ESA) Rosalind Franklin rover from Kennedy Space Center in Florida, no earlier than late 2028. It would mark the first time SpaceX has ever sent a payload to Mars.

Under NASA’s Rosalind Franklin Support and Augmentation project, known as ROSA, the agency is providing braking engines for the rover’s descent stage, radioisotope heater units that use decaying plutonium to keep the rover warm on the Martian surface, additional electronics, and a mass spectrometer instrument, as noted by SpaceNews.

Those nuclear heating units are the reason an American rocket was required at all. U.S. export controls on radioisotope technology mean any payload carrying them must launch on a domestic vehicle, which narrowed the field to SpaceX and United Launch Alliance. Falcon Heavy’s pricing made it the practical choice.

SpaceX is quietly becoming the U.S. Military’s only reliable rocket

Falcon Heavy debuted in February 2018 and has 11 launches to its record. The rocket has not flown since October 2024, when it sent NASA’s Europa Clipper toward Jupiter. The three-core design, built from modified Falcon 9 first stages, gives it the lift capacity needed for deep space planetary missions that a single Falcon 9 cannot reach.

The Rosalind Franklin rover has been sitting in storage in Europe for years. It was originally due to launch in 2022 as a joint mission with Russia, but Russia’s invasion of Ukraine ended that partnership, leaving the rover built but stranded without a launch vehicle or landing hardware. NASA stepped back in through a 2024 agreement with ESA to rescue the mission. The rover is designed to drill up to two meters below the Martian surface in search of evidence of past life, a science objective no previous mission has attempted at that depth.

The contradiction at the center of this story is hard to ignore. The White House’s fiscal year 2027 budget proposal included no funding for ROSA and did not mention the mission at all in the detailed congressional justification document released April 3.

Musk has long argued that reaching Mars is not optional. “We don’t want to be one of those single planet species, we want to be a multi-planet species.” Whether this particular mission survives Washington’s budget fight, the Falcon Heavy contract means SpaceX is now formally on record as the rocket that could get humanity’s next Mars science mission off the ground.

The timing of this contract carries extra weight given that SpaceX filed confidentially with the SEC in early April and is targeting an IPO roadshow in the week of June 8. It would be the largest public offering in history.

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