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Tesla battery researchers open path to all-electric range extender concept

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Tesla has solidified itself as an industry leader when it comes to electric vehicles and their range. However, an EV’s range could always be improved, and the company has taken great efforts to make this possible. One of these was outlined by Tesla’s battery researchers, who recently published the results of a test that cycles lithium metal on graphite to form hybrid lithium-ion/lithium metal cells. This particular innovation could open the door to an all-electric range extender.

Other automakers have used range extenders in the past, but they’ve been comprised of small petrol-powered engines that are used as a generator to recharge the vehicle’s battery pack when it is low on range. The process of cycling lithium metal on graphite, on the other hand, could lead to a 20% higher energy density than the traditional lithium-ion cells that power the Tesla’s vehicles.

Tesla’s battery research team, led by Jeff Dahn of Dalhousie University, has found a way to create a range extender of sorts without having to keep a small gas engine in the vehicle. Tesla detailed its findings in a research paper that was published to ScienceDirect on April 30. Titled “Cycling Lithium Metal on Graphite to Form Hybrid Lithium-Ion/Lithium Metal Cells,” Dahn and his researchers outlined the testing process.

The findings proved a possible 20% increase in range when using the range extender, which is comprised of “hybrid cells” that use Lithium-Ion and Lithium Metal. The cells also used an optimized electrolyte, and pressure enabled reversible plating on graphite.

The paper states:

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“A hybrid anode cell design is proposed involving lithium metal plating on top of graphite that provides a 20% increase in energy density over conventional lithium-ion cells. Pouch cells with hybrid graphite-lithium metal anodes cycled with conventional electrolytes fell below 80% capacity in under 15 cycles. However, with a dual-salt electrolyte and applied mechanical pressure optimized for lithium metal cycling, hybrid cells achieved over 150 full (100% utilization) cycles before falling below 80% capacity with a CE of 99.6% for lithium metal plating on graphite.

“We also found that intermittent high energy (100% utilization) cycles utilizing lithium metal can be dispersed among hundreds of conventional lithium-ion cycles where only the graphite is utilized. Operating the cell with this intermittent protocol shows minimal impact to the underlying graphite capacity. Therefore, these hybrid cells can operate well in “lithium-ion mode” with periodic high energy full cycles accessing the lithium metal capacity.”

Tesla’s new findings show that increased energy density is made possible with the hybrid concept. When combining lithium-ion cells with lithium metal, energy density improves as the graphite anode utilized in traditional lithium-ion cells is not capable of handling the increased energy. The utilization of a dual-salt electrolyte also increases density and decreases battery cell degradation.

Tesla’s battery researchers described the advantages of the hybrid lithium-ion/lithium metal cells in the discussion below.

“If an electric vehicle with a conventional lithium-ion battery can deliver a range of 400 km, then hybrid cells could enable a range of 480 km. By capping the upper cut-off voltage of hybrid cells to operate in lithium-ion mode, the average cell voltage and delivered capacity will decrease. As a result, operating a hybrid cell in lithium-ion mode delivers an energy density of 530Wh/L, about 25% less than a conventional lithium-ion cell.

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“This would result in a range of 300 km. In a study of driving behavior for EVs, Smart et al.34 showed that only 1% of daily trips are longer than 325 km on average. Therefore, operating hybrid cells most of the time in lithium-ion mode enabling a range of 300 km, while periodically using the lithium metal portion for long > 400 km trips, as mimicked by this testing protocol, should be viable for most drivers.”

It should be noted that the Tesla battery researchers’ study is only in their initial stages. Thus, it may take some time before the technology gets rolled out to Tesla’s fleet. The wait would likely be worth it though, as the hybrid cells could open the door to all-electric vehicles with range extender features. This would be incredibly useful for electric vehicle owners who take long road trips with family, and it could also be a notable step towards EVs gaining range parity with their petrol-powered counterparts.

Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Tesla Giga Shanghai celebrates 5 million electric drive unit milestone

The milestone was celebrated by the company in a post on its official Weibo account.

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Tesla China has reached another manufacturing milestone at Gigafactory Shanghai, rolling out the facility’s 5 millionth locally produced drive unit. 

The milestone was celebrated by the company in a post on its official Weibo account. In its post, the Giga Shanghai team could be seen posing with the 5 millionth drive unit.

Giga Shanghai’s major benchmark

The milestone drive unit was produced at Gigafactory Shanghai, which produces the Model Y and the Model 3. In a release, Tesla China noted that its three-in-one integrated electric drive system combines the motor, gearbox, and inverter into a single compact assembly. This forms a powerful “heart” for the company’s electric cars.

Tesla China also noted that its drive units’ integrated design improves energy conversion efficiency while reducing overall weight and complexity, benefits that translate into stronger performance, improved handling, and longer service life for its vehicles.

Credit: Tesla China

The new milestone builds on earlier achievements at the same site. In July 2024, Tesla announced that its 10 millionth electric drive system globally had rolled off the line at the Shanghai plant, making it the first self-produced Tesla component to reach that volume. 

More recently, the factory also produced its 4 millionth China-made vehicle, a Model Y L. The factory has also continued hitting global production milestones, rolling out Tesla’s 9 millionth EV worldwide late last year, with the landmark vehicle being a Tesla Model Y.

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Tesla China’s role

Construction of Giga Shanghai began in January 2019, with production starting by the end of that year. This made it the first wholly foreign-owned automotive manufacturing project in China. The facility began delivering Model 3 vehicles locally in early 2020 and added Model Y production in 2021. The plant is now capable of producing about 1 million vehicles annually.

Credit: Tesla China

Throughout 2025, Giga Shanghai delivered 851,732 vehicles, representing a 7.08% year-on-year decline, according to data compiled by CNEVPost. Even so, recent months showed renewed momentum

In December alone, Tesla China recorded wholesale sales of 97,171 vehicles, including domestic deliveries and exports, making it the company’s second-best monthly total on record, per data from the China Passenger Car Association. Retail sales during December reached roughly 94,000 units, up about 13% year over year.

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Investor's Corner

Tesla price target boost from its biggest bear is 95% below its current level

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Credit: Tesla China

Tesla stock (NASDAQ: TSLA) just got a price target boost from its biggest bear, Gordon Johnson of GLJ Research, who raised his expected trading level to one that is 95 percent lower than its current trading level.

Johnson pushed his Tesla price target from $19.05 to $25.28 on Wednesday, while maintaining the ‘Sell’ rating that has been present on the stock for a long time. GLJ has largely been recognized as the biggest skeptic of Elon Musk’s company, being particularly critical of the automotive side of things.

Tesla has routinely been called out by Johnson for negative delivery growth, what he calls “weakening demand,” and price cuts that have occurred in past years, all pointing to them as desperate measures to sell its cars.

Johnson has also said that Tesla is extremely overvalued and is too reliant on regulatory credits for profitability. Other analysts on the bullish side recognize Tesla as a company that is bigger than just its automotive side.

Many believe it is a leader in autonomous driving, like Dan Ives of Wedbush, who believes Tesla will have a widely successful 2026, especially if it can come through on its targets and schedules for Robotaxi and Cybercab.

Justifying the price target this week, Johnson said that the revised valuation is based on “reality rather than narrative.” Tesla has been noted by other analysts and financial experts as a stock that trades on narrative, something Johnson obviously disagrees with.

Dan Nathan, a notorious skeptic of the stock, turned bullish late last year, recognizing the company’s shares trade on “technicals and sentiment.” He said, “From a trading perspective, it looks very interesting.”

Tesla bear turns bullish for two reasons as stock continues boost

Johnson has remained very consistent with this sentiment regarding Tesla and his beliefs regarding its true valuation, and has never shied away from putting his true thoughts out there.

Tesla shares closed at $431.40 today, about 95 percent above where Johnson’s new price target lies.

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I subscribed to Tesla Full Self-Driving after four free months: here’s why

It has been incredibly valuable to me, and that is what my main factor was in considering whether to subscribe or not. It has made driving much less stressful and much more enjoyable.

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Credit: Teslarati

I have been lucky enough to experience Tesla Full Self-Driving for the entire duration of my ownership experience for free — for four months, I have not had to pay for what I feel is the best semi-autonomous driving suite on the market.

Today, my free trial finally ran out, and I had two choices: I could go without it for a period until I felt like I absolutely needed it, or I could subscribe to it, pay $99 per month, and continue to experience the future of passenger transportation.

I chose the latter, here’s why.

Tesla Full Self-Driving Takes the Stress Out of Driving

There are a handful of driving situations that I don’t really enjoy, and I think we all have certain situations that we would just rather not encounter. This is not to say that I won’t ever experience them as someone who has driven a car for 15 years (it feels weird saying that).

I don’t love to drive in cities; I really don’t like driving on I-695 on my way to Baltimore, and I truly hate parallel parking. All three things I can do and have done, all three within the past few weeks, too.

However, if I can avoid them, I will, and Tesla Full Self-Driving does that for me.

Tesla Full Self-Driving Eliminates the Monotony

I drive to my alma mater, Penn State University, frequently in the Winter as I am a season ticket holder to Wrestling and have been for 16 years now.

The drive to State College is over two hours and over 100 miles in total, and the vast majority of it is boring as I travel on Rt 322, which is straight, and there is a lot of nature to look at on the way.

I am willing to let the car drive me on that ride, especially considering it is usually very low traffic, and the vast majority of it is spent on the highway.

The drive, along with several others, is simply a boring ride, where I’d much rather be looking out the windshield and windows at the mountains. I still pay attention, but having the car perform the turns and speed control makes the drive more enjoyable.

Tesla Full Self-Driving Makes Navigating Easier

Other than the local routes that I routinely travel and know like the back of my hand, I’ve really enjoyed Full Self-Driving’s ability to get me to places — specifically new ones — without me having to constantly check back at the Navigation.

Admittedly, I’ve had some qualms with the Nav, especially with some routing and the lack of ability to choose a specific route after starting a drive. For example, it takes a very interesting route to my local Supercharger, one that nobody local to my area would consider.

But there are many times I will go to a new palce and I’m not exactly sure where to go or how to get there. The Navigation, of course, helps with that. However, it is really a luxury to have my car do it for me.

To Conclude

There was no doubt in my mind that when my Full Self-Driving trial was up, I’d be subscribing. It was really a no-brainer. I am more than aware that Full Self-Driving is far from perfect, but it is, without any doubt, the best thing about my Tesla, to me.

It has been incredibly valuable to me, and that is what my main factor was in considering whether to subscribe or not. It has made driving much less stressful and much more enjoyable.

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