Tesla’s Battery Day detailed a variety of topics that are related to the future of cell manufacturing efficiency. However, the presentation also showed how the automaker is improving the design of its vehicles by utilizing a new battery architecture. Tesla plans to adopt the same strategy within its vehicles to improve mass, range, and the structural integrity of its vehicles.
Teslarati reported earlier this year that Tesla would be using a single-piece casting design on the Model Y. The improved casting eliminates 79 parts per car, which not only increases manufacturing efficiency but also increases safety for drivers. The cost of each vehicle’s rear underbody design also decreases by 40% thanks to the casting, which is performed by a massive machine known as the Giga Press.
The single-piece rear casting is made from Tesla’s own high-pressure aluminum alloy that has a high strength thanks to no heat treatment or coatings that would take away from the structural integrity of the design. Heat treating a casting of this size after manufacturing causes deformation, CEO Elon Musk said during the event.
However, the manufacturing team at Tesla also drew inspiration from aircraft wings to improve the structural integrity of its vehicles. While the casting improves manufacturing efficiency and strength, the positioning of structural batteries eliminates excess structure from the battery packs, increasing density.
“The non-cell portion of the battery has negative mass,” Musk said. “We saved more mass in the rest of the vehicle than in the non-cell portion of the battery. So how do you really minimize the mass of the battery? Make it negative.”
The minimization of negative mass allowed the automaker to increase the density of the battery pack. Individual cells could be positioned more efficiently because excessive structures within the pack itself were eradicated. The new Tesla battery design is completely free of any negative mass, which improves pack density along with structural integrity.
“The pack itself is structural,” Musk stated.
Additionally, the filler within the Model 3 and Model Y packs, which currently uses a flame retardant, now uses a structural adhesive and flame retardant. This adhesive effectively attaches the cells to the top and bottom sheets of the pack. “This allows you to do sheer transfer between the upper and lower sheet,” which increases stiffness and prevents major deformation in the event of a crash.
Improvements in the casting design of Tesla’s future cars and the newly designed battery architecture, which uses new materials and strategies to increase stiffness, will increase the already safe vehicles that the company manufactures. Tesla already holds three separate five-star crash safety ratings with the Model S, Model 3, and Model X. The Model Y has not yet been tested, but the vehicle does use the one-piece rear casting design already at the Fremont production facility.
Tesla’s Battery Day did not disappoint. While the blueprint to cell manufacturing efficiency was laid out, the company also showed how battery layout and architecture could increase Tesla’s vehicle safety. The new design revolutionizes EVs as a whole and will eventually lead to more safety than previously displayed.
Investor's Corner
Tesla ‘Model Q’ gets bold prediction from Deutsche Bank that investors will love
Tesla’s Model Q could be on the way soon, and a new note from Deutsche Bank thinks it will contribute to Q4 deliveries.

The Tesla “Model Q” has been in the rumor mill for the company for several years, but a recent note from Wall Street firm Deutsche Bank seems to indicate that it could be on its way in the near future.
This comes as Tesla has been indicating for several quarters that its development of affordable models was “on track” for the first half of 2025. The company did not say it would unveil the vehicles in the first half, but many are anticipating that more cost-friendly models could be revealed to the public soon.
Potential affordable Tesla “Model 2/Model Q” test car spotted anew in Giga Texas
The Deutsche Bank note refers to one of the rumored affordable models as the “Model Q,” but we’ve also seen it referred to as the “Model 2,” amongst other names. Tesla has not officially coined any of its upcoming vehicles as such, but these are more of a universally accepted phrase to identify them, at least for now.
The rumors stem from sentiments regarding Tesla’s 2025 delivery projections, which are tempered as the company seeks to maintain a steady pace compared to 2023 and 2024, when it reported 1.8 million deliveries.
Deutsche Bank’s analysts believe the deliveries could be around 1.58 million, but they state this is a cautious stance that could be impacted by several things, including the potential launch of the Model Q, which they believe will make its way to market in Q4:
“Looking at the rest of the year, we maintain a cautious stance on volume calling for 1.58m vehicle deliveries (-12% YoY) vs. consensus +1.62m, with the timing of Model Q rollout as the key swing factor (we now assume only 25k in Q4). In China, Tesla will introduce the Model Y L this fall (6 inch longer wheel base allowing for larger 3-row seating with six seats).”
Interestingly, the same firm also predicted that the Model Q would launch in the first half of the year based on a note that was released in early December 2024.
Those estimations came from a reported meeting that Deutsche Bank had with Tesla late last year, where it said it aimed to launch the Model Q for less than $30,000 and aimed for it to compete with cars like the Volkswagen ID.3 and BYD Dolphin.
Tesla’s Q2 Earnings Call is slated for this Wednesday and could reveal some additional details about the affordable models.
Elon Musk
Tesla preps to expand Robotaxi geofence once again, answering Waymo
Just days after Waymo responded to them, Tesla is preparing for a potentially massive expansion of the Robotaxi geofence.

Tesla is preparing to expand its Robotaxi geofence yet again, just days after Waymo responded to its initial broadening of the area.
Tesla launched its first expansion last week, less than a month after introducing Robotaxi rides in Austin.
The company opted for a very interesting shape for its geofence expansion, which was more of an indication that it could launch more rides in virtually any area of the city due to the new geofence it chose.
Waymo then responded to Tesla shortly after with an expansion of its own. After Tesla’s first expansion of its geofence, it had 42 square miles of Robotaxi-accessible travel region. This was larger than Waymo’s 37 square miles.
However, the Waymo expansion last week brought the company to a substantial 90 square miles of Austin:
Waymo responds to Tesla’s Robotaxi expansion in Austin with bold statement
Tesla appears to be ready to respond. Drone operator and Gigafactory Texas observer Joe Tegtmeyer spotted Tesla Robotaxi validation vehicles well west of downtown Austin in the area of Marble Falls, Texas.
This would significantly increase Tesla’s square mileage if it could manage to bring its geofence to that size:
🚨 We could see Tesla’s response to Waymo’s expansion in Austin very soon
Based on Tesla’s expansion last time, it’s safe to assume they can go to any area of Austin whenever they choose
It’s not a coincidence they chose, well, you know, the shape they did 🤣 https://t.co/xB92SQ1ntC
— TESLARATI (@Teslarati) July 19, 2025
The two companies are not directly responding to one another with these expansions, but it appears that there is a significant amount of competition underway, which ultimately benefits the consumers.
Waymo has been operating in Texas since March from a fully public perspective, while Tesla is still slowly expanding its test size for the Robotaxi fleet on a nearly daily basis. Tesla launched Robotaxi rides to a handful of Early Access Program members on June 22.
Tesla is also expanding to other regions of the United States, particularly in Arizona and California. However, the Texas expansion is a priority currently, as it is the only region where Tesla has received approval to operate passenger rides in a driverless setting in the country.
Elon Musk
Elon Musk confirms awesome new features at Tesla Diner Supercharger
More details continue to be revealed about the Tesla Supercharger Diner as its opening seems to be imminent.

Elon Musk has confirmed a few new features that will be present at the Tesla Diner Supercharger in Los Angeles.
Musk confirmed these two new details as he revealed he recently ate at the Supercharger Diner. We also recently confirmed a few menu items as a soft launch has already occurred, and a public launch date appears to be within reach.
The new features were revealed by Tesla Joy on X. We shared the details, and Musk confirmed that these are, in fact, features of the Diner that Tesla owners will be able to enjoy.
Tesla reveals key detail of Supercharger Diner, but it’s bigger than you think
The Diner is not exclusive to Tesla owners, but these two features do require a Tesla for compatibility purposes.
Order Food from Your Car
As you pull into the Supercharger Diner, you can order any food item you want, including burgers, wings, fries, shakes, cookies, and more, directly from your vehicle.
A prompt will likely appear that will open a menu to the Supercharger Diner, allowing you to order food. An employee will bring the food out, that is, if Tesla decides to continue with a true and traditional 50s diner theme.
We get it, it’s not a groundbreaking feature. It’s still cool, convenient, and another advantage to visit the diner as a Tesla owner.
Movie Screen Audio Will Sync to Your Tesla
There are two massive movie screens that will play various entertainment options during your visit to the Supercharger Diner. There have been movie clips and even SpaceX launch highlights playing during recent drone flyovers at the location on Santa Monica Boulevard.
Instead of having to open your windows to hear the content on the screen, it will instead sync the audio and play directly in your vehicle through your car stereo speakers.
True
— Elon Musk (@elonmusk) July 18, 2025
The Supercharger Diner has also appeared on the Tesla app for the first time, and is currently showing 80 stalls at the location:
🚨 The Tesla Diner is now showing up on the phone app.
80 Superchargers!!! pic.twitter.com/fdN2MzyZCg
— TESLARATI (@Teslarati) July 18, 2025
Although the stalls are not yet active, the culmination of all the details we’ve learned over the past week about the Diner only points to one thing: an imminent grand opening.
Tesla has not yet confirmed a date for the Supercharger Diner’s opening, and Los Angeles building and construction permits also do not state a specific target date for opening.
It seems as if Tesla will reveal the date itself, potentially in the coming week, as it will report earnings on Wednesday, July 23.
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