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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. 

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. 

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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. 

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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Elon Musk

SpaceX just cleared a key FCC hurdle in its fight with Verizon and AT&T

The FCC accepted SpaceX’s bid for Grain’s 800 MHz spectrum, opening review for Starlink Mobile.

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A hand holds a smartphone displaying the Starlink Mobile app interface showing a strong “Connected – Direct to Cell” signal, with a Starlink satellite beaming connectivity signals down to Earth from orbit. The background features the planet’s night side glowing with city lights against the curve of the atmosphere, set above a scenic twilight landscape.

The Federal Communications Commission has formally opened its review of SpaceX’s plan to buy a nationwide block of 800 MHz spectrum from Grain Management, moving Starlink Mobile one step closer to operating as a full U.S. wireless carrier.

In a public notice issued Tuesday, the FCC’s Wireless Telecommunications Bureau said it accepted for filing the applications to transfer control of two Grain license companies, Prism License Co. 1 and Prism License Co. 2, to Starlink Spectrum Holdings, a wholly owned SpaceX subsidiary. The deal covers 546 paired licenses across 3,224 counties, reaching roughly 100% of the U.S. population in all 50 states, Washington, D.C., Puerto Rico and the U.S. Virgin Islands. The proceeding sits under WT Docket No. 26-313.

Acceptance is not approval. It means the applications cleared an initial review and the public comment window is now open. Comments and petitions to deny are due December 1, and oppositions are due December 8. The bureau also said the conditions attached to Grain’s July purchase of the licenses from T-Mobile, which require rapid buildout for terrestrial and direct to device service, would carry over to SpaceX if the transfer is approved.

SpaceX announced the agreement on October 8, saying the new airwaves would let Starlink Mobile’s signal reach phones inside buildings, something its 2 GHz spectrum from EchoStar cannot do as well. The portfolio includes up to 14 MHz of paired spectrum in the 817 to 824 MHz and 862 to 869 MHz bands, which most existing phones already support. Elon Musk called it “the last critical piece of the spectrum puzzle needed for SpaceX to provide complete phone coverage in America.”

According to the filing, SpaceX would hold up to 89 MHz of total spectrum in any given market after the deal closes, including up to 14 MHz below 1 GHz. That is far under the 385 MHz threshold the FCC uses to flag a transaction for closer competitive scrutiny, and well short of the roughly 300 MHz each of AT&T, Verizon and T-Mobile holds.

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Tuesday’s notice does not decide how SpaceX can use the spectrum from orbit. A separate application SpaceX filed on October 27 seeking authority to provide supplemental coverage from space on the same frequencies, along with related waiver requests, is still pending before the commission.

The ground network is already taking shape. Last week, SpaceX picked Qualcomm to supply radios, baseband units and software for a nationwide 5G build, with deployment across tens of thousands of U.S. cell sites starting in 2027. The FCC also voted on October 29 to advance a proposal opening another 482 MHz to direct to device service, though AT&T, Verizon and T-Mobile hacritive pushed to strip nearly 300 MHz from it. SpaceX President Gwynne Shotwell has said service on SpaceX’s own airwaves is targeted for early 2028.

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Cybertruck

Tesla upfitter offers to keep Cybertruck alive

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Credit: Unplugged Performance

A Tesla upfitter has offered to take over Cybertruck lines from the company in a last-ditch effort to save the all-electric pickup from being completely canceled in the middle of 2027.

Unplugged Performance, the Hawthorne, California-based Tesla aftermarket specialist, has publicly offered to take over Cybertruck production from Tesla, funding the effort “through a consortium of investors.”

The proposal comes as Tesla prioritizes its Cybercab Robotaxi program and prepares to wind down Cybertruck assembly at Gigafactory Texas around mid-2027.

Founded in 2013 by Ben Schaffer and located adjacent to Tesla’s Design Studio and SpaceX, Unplugged Performance has become a leading provider of premium upgrades for Tesla vehicles, including extensive Cybertruck packages under its UP INVINCIBLE line.

Through its UP.FIT division, the company has also developed purpose-built police and fleet versions of the Cybertruck, including deliveries to agencies such as the Las Vegas Metropolitan Police Department.

In an X post on Tuesday, Unplugged said:

“An open offer to Tesla: We fully support putting Cybercab first, and we’d be glad to take the Cybertruck line off your hands. We’d fund it with a consortium of investors and run it at no cost to Tesla’s floor space, headcount, or focus. All of that goes to Cybercab. Cybercab gets first call on battery cells too. We’ll wait our turn. Tesla gains incremental profit: a license fee, plus FSD and Robotaxi network revenues on every vehicle built. We’d build the Cybertruck, a three-row CyberSUV, and an unmanned CyberCargo hauler. More autonomous miles, across every surface of this planet and beyond. Worth a conversation?”

The arrangement would free Tesla resources and manufacturing capacity for Cybercab while allowing continued production of the stainless-steel pickup and expanded variants. Unplugged Performance indicated it would wait for battery cells after Cybercab needs are met and would generate ongoing revenue for Tesla through licensing and software/network services on the vehicles it produces.

Following strong initial interest, Unplugged Performance posted a follow-up inviting potential investors and strategic partners to email cyber@unpluggedperformance.com. The company clarified that the outreach is solely to gauge interest and does not constitute an offer to sell securities or acceptance of funds at this stage.

The proposal arrives shortly after Elon Musk indicated that Cybertruck production in Texas would be phased out by roughly the middle of 2027 to expand Cybercab output.

Whether Tesla engages with the offer remains to be seen, but the public overture highlights both the aftermarket specialist’s deep experience with the Cybertruck platform and the growing focus on autonomy within Tesla’s manufacturing plans.

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Elon Musk

Elon Musk says Tesla Cybercab future is ‘obvious to anyone with eyes and a brain’

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Elon Musk said the Tesla Cybercab will perform “a majority of all passenger miles” where it is allowed to operate and that point is “obvious to anyone with eyes and a brain.”

Musk used the point to double down on the company’s decision to ax the cult-favorite Cybertruck, as its production space will be removed and transitioned into additional Cybercab lines. The move has catalyzed a polarizing conversation on whether its right or wrong.

Whatever side you are on — it’s happening.

Regardless, Musk seems to be getting to the point that he is done talking about the choice. At some point, you have to think that this was truly a difficult decision for him and the company as well, and this is not something he took lightly. In fact, he’s probably a little bit disappointed with it, too.

But the point remains that the Cybertruck is gone. Musk’s focus is purely on developing an autonomous platform that the world will utilize for transportation, and he’s telling you that anyone “with eyes and a brain” can see it:

Tesla is betting that all of its passengers in the future will be okay with not owning their own personal cars and will be fine with ride-hailing for the rest of their lives. Every dinner, every errand, every trip to the airport and transportation thereafter, will all be operated by ride-sharing, and in Tesla’s perfect world, it will happen in a Cybercab.

As of now, Cybercab is only active in Austin, but it has been spotted all over the country with a driver behind the wheel in those prototypes. In Austin, the car has no steering wheel or pedals for people to control the vehicle.

The Cybertruck dilemma is one that has truly come across the entire Tesla community and while it seems to be a great idea to keep it because people love it, the business side of things is steering Musk and Tesla in another direction.

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