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Tesla battery researchers open path to all-electric range extender concept
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:
“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.
“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.
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Tesla targets production increase at Giga Berlin in 2026
Plant manager André Thierig confirmed the facility’s stable outlook to the DPA, noting that Giga Berlin implemented no layoffs or shutdowns amid challenging market conditions.
Tesla is looking positively toward 2026 with plans for further growth at its Grünheide factory in Germany, following steady quarterly increases throughout 2025.
Plant manager André Thierig confirmed the facility’s stable outlook to the Deutsche Presse-Agentur (DPA), noting that Giga Berlin implemented no layoffs or shutdowns despite challenging market conditions.
Giga Berlin’s steady progress
Thierig stated that Giga Berlin’s production actually rose in every quarter of 2025 as planned, stating: “This gives us a positive outlook for the new year, and we expect further growth.” The factory currently supplies over 30 markets, with Canada recently being added due to cost advantages.
Giga Berlin’s expansion is still underway, with the first partial approval for capacity growth being secured. Preparations for a second partial approval are underway, though the implementation of more production capacity would still depend on decisions from Tesla’s US leadership.
Over the year, updates to Giga Berlin’s infrastructure were also initiated. These include the relocation of the Fangschleuse train station and the construction of a new road. Tesla is also planning to start battery cell production in Germany starting 2027, targeting up to 8 GWh annually.
Resilience amid market challenges
Despite a 48% drop in German registrations, Tesla maintained Giga Berlin’s stability. Thierig highlighted this, stating that “We were able to secure jobs here and were never affected by production shutdowns or job cuts like other industrial sites in Germany.”
Thierig also spoke positively towards the German government’s plans to support households, especially those with low and middle incomes, in the purchase and leasing of electric vehicles this 2026. “In our opinion, it is important that the announcement is implemented very quickly so that consumers really know exactly what is coming and when,” the Giga Berlin manager noted.
Giga Berlin currently employs around 11,000 workers, and it produces about 5,000 Model Y vehicles per week, as noted in an Ecomento report. The facility produces the Model Y Premium variants, the Model Y Standard, and the Model Y Performance.
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Tesla revamped Semi spotted, insane 1.2 MW charging video releases
These developments highlight Tesla’s ongoing refinements to the vehicle’s design and infrastructure.
Tesla is gearing up for high-volume Semi production in 2026, with the Class 8 all-electric truck’s revamped variant being spotted in the wild recently. Official footage from Tesla also showed the Semi achieving an impressive 1.2 MW charging rate on a charger.
These developments highlight Tesla’s ongoing refinements to the vehicle’s design and infrastructure.
Revamped Tesla Semi sighting
Tesla Semi advocate @HinrichsZane, who has been chronicling the progress of the vehicle’s Nevada factory, recently captured exclusive drone footage of the refreshed Class 8 truck at a Megacharger stall near Giga Nevada. The white unit features a full-width front light bar similar to the Model Y and the Cybercab, shorter side windows, a cleared fairing area likely for an additional camera, and diamond plate traction strips on the steps.
Overall, the revamped Semi looks ready for production and release. The sighting marks one of the first real-life views of the Class 8 all-electric truck’s updated design, with most improvements, such as potential 4680 cells and enhanced internals, being hidden from view.
1.2 MW charging speed and a new connector
The official Tesla Semi account on X also shared an official video of Tesla engineers hitting 1.2 MW sustained charging on a Megacharger, demonstrating the vehicle’s capability for extremely rapid charging. Tesla Semi program lead Dan Priestley confirmed in a later post on X that the test occurred at a dedicated site, noting that chargers at the Semi factory in Nevada are also 1.2 MW capable.
The short video featured a revamped design for the Semi’s charging port, which seems more sleek and akin to the NACS port found in Tesla’s other vehicles. It also showed the Tesla engineers cheering as the vehicle achieved 1.2 MW during its charging session. Dan Priestley explained the Semi’s updated charging plug in a post on X.
“The connector on the prior Semi was an early version (v2.4) of MCS. Not ‘proprietary’ as anyone could have used it. We couldn’t wait for final design to have >1MW capability, so we ran with what had been developed thus far. New Semi has latest MCS that is set to be standard,” the executive wrote in a post on X.
Check out the Tesla Semi’s sighting at the Nevada factory in the video below.
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Tesla FSD successfully completes full coast-to-coast drive with zero interventions
Tesla community members celebrated the milestone on X, and the feat earned praise from some of the electric vehicle maker’s executives.
A Tesla owner has successfully completed a full coast-to-coast drive across the United States on Full Self-Driving (FSD) Supervised. The trip was accomplished with zero interventions.
Tesla community members celebrated the milestone on X, and the feat earned praise from some of the electric vehicle maker’s executives.
FSD Coast-to-Coast
The coast-to-coast feat was accomplished by Tesla owner Davis Moss, who drives a stealth gray Model 3 with AI4 hardware. Based on data from the FSD database and a community tracker, the last 10,638.8 miles Moss drove in his Model 3 were completed using FSD 100% of the time. His vehicle is equipped with FSD v14.2.1.25, which was installed 12 days ago.
As per Moss in a celebratory post on X, his Model 3 was able to complete a full coast-to-coast drive across the United States in 2 days and 20 hours. His trip started at the Tesla Diner in Los Angeles, CA, and it ended in Myrtle Beach, SC. Overall, his trip spanned 2,732.4 miles.
“This was accomplished with Tesla FSD V14.2 with absolutely 0 disengagements of any kind even for all parking including at Tesla Superchargers,” Moss stated in his post. He also added in later comments that there were zero close calls during the trip.
Tesla community celebrates
The FSD milestone trip was widely lauded by members of the Tesla community, especially since a coast-to-coast drive with zero interventions has been cited by Elon Musk as a target since October 2016, when Autopilot 2.0 was unveiled. At the time, Musk initially estimated that a coast-to-coast drive across the United States should be possible by the end of 2017. Considering Moss’ feat in his Model 3, it appears that Elon Musk’s estimate was not impossible at all. It was just late.
Musk himself celebrated the milestone on X, and so did Tesla VP of AI Software Ashok Elluswamy, who wrote “World’s first fully autonomous coast-to-coast drive, done with Tesla self-driving v14. Congrats and thank you @DavidMoss!” in a post on X. The official Tesla North America account also celebrated the feat, writing “First Tesla to drive itself from coast to coast w/ FSD Supervised. 0 interventions, all FSD” on X.
Tesla targets production increase at Giga Berlin in 2026
Tesla revamped Semi spotted, insane 1.2 MW charging video releases
