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Tesla outlines its ideas for the Structural Battery Pack

Credit: Tesla

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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.

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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.

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

Energy

Tesla launches first Virtual Power Plant in UK – get paid to use solar

Tesla has launched its first-ever Virtual Power Plant program in the United Kingdom.

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Credit: Tesla Energy | X

Tesla has launched its first-ever Virtual Power Plant program in the United Kingdom. This feature enables users of solar panels and energy storage systems to sell their excess energy back to the grid.

Tesla is utilizing Octopus Energy, a British renewable energy company that operates in multiple markets, including the UK, France, Germany, Italy, Spain, Australia, Japan, New Zealand, and the United States, as the provider for the VPP launch in the region.

The company states that those who enroll in the program can earn up to £300 per month.

Tesla has operated several VPP programs worldwide, most notably in California, Texas, Connecticut, and the U.S. territory of Puerto Rico. This is not the first time Tesla has operated a VPP outside the United States, as there are programs in Australia, Japan, and New Zealand.

This is its first in the UK:

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Tesla is not the only company that is working with Octopus Energy in the UK for the VPP, as it joins SolarEdge, GivEnergy, and Enphase as other companies that utilize the Octopus platform for their project operations.

It has been six years since Tesla launched its first VPP, as it started its first in Australia back in 2019. In 2024, Tesla paid out over $10 million to those participating in the program.

Tesla VPP program in California hits new capacity milestone

Participating in the VPP program that Tesla offers not only provides enrolled individuals with the opportunity to earn money, but it also contributes to grid stabilization by supporting local energy grids.

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Waymo responds to Tesla’s Robotaxi expansion in Austin with bold statement

Waymo and Tesla are surely in a battle of “mine’s bigger” right now.

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Credit: Waymo

Waymo has responded to Tesla’s Robotaxi expansion in Austin with a bold statement by extending its own geofence by a considerable margin.

Earlier this week, Tesla chose to expand its geofence for its driverless Robotaxi service in Austin, Texas, substantially. The geofence more than doubled, bringing Tesla’s total serviceable area within Austin to approximately 42 square miles.

Tesla’s Robotaxi geofence in Austin grows, and its shape is hard to ignore

This put Tesla ahead of Waymo in terms of its service area in Austin, as the company’s geofence was just 37 square miles.

We reported on how significant this statement was for Tesla, as it has only been operating its driverless Robotaxi platform in Austin for less than a month, compared to Waymo, which has been there since March.

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Tesla Robotaxi has already surpassed Waymo in this key metric

Waymo took it as a challenge, it seems, and expanded its geofence, and it did it impressively and massively. Now, Waymo’s geofence spans 90 square miles within Austin, including new neighborhoods such as Crestview, Windsor Park, Sunset Valley, Franklin Park, as well as popular tourist destinations like The Domain and McKinney Falls State Park.

The move “unlocks another key milestone in Austin as our operating territory with Waymo expands from 37 to 90 square miles, which means that even more riders can experience Waymo’s fully autonomous vehicles through the Uber app,” Sarfraz Maredia, Global Head of Autonomous Mobility & Delivery at Uber, said.

Additionally, Shweta Shrivastava, Senior Director of Product Management at Waymo, said:

“Just months after serving our first Austin riders with Uber, we’re excited to offer our 24/7 service to more of the city. The service with our partners at Uber is healthy, and we are ready for more Austinites to experience the magic of fully autonomous driving. Austin remains one of the fastest growing cities in the country, and we are doing our part to grow with it.”

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Across the U.S., this expansion brings Waymo’s service area to more than 700 square miles, as it also operates in California and Arizona.

Here’s what the two geofenced regions look like:

The competition between Waymo and Tesla only benefits consumers, as the two companies are evidently sparring for a larger service area in Austin. Tesla launched its interestingly-shaped geofence expansion on Monday, and it seemed that the shape was more of a joke that could also be construed as a warning to competitors.

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Tesla could more than likely have pushed its geofence to a larger size, but it purposely chose to do so in a comical fashion.

Now that Waymo has responded in this way, we’ll see if Tesla puts the jokes aside.

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Tesla exec hints at useful and potentially killer Model Y L feature

The Model Y L could become the company’s vehicle that offers the best balance between utility and comfort.

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Credit: Tesla China

A Tesla executive from China has hinted at what could very well be a killer feature for the upcoming Model Y L. If speculations prove accurate, the Model Y L could become the company’s vehicle that offers the best balance between utility and comfort, possibly even exceeding what is offered by Tesla’s flagship vehicles.

Model Y L teaser

The Tesla Model Y L is expected to be a six-seat version of the best-selling all-electric crossover. With its six seats, the new Model Y L would be able to provide ample leg room to third-row passengers—something that the seven-seat Model Ys produced in the United States were unable to do.

With six seats, the Model Y L would be closer in size and more similar to the larger and much more expensive Model X, which remains Tesla’s de facto family hauler. The six-seat Model X, however, has one flaw that makes it a bit less useful than its seven-seat variant–its second row seats don’t fold fully flat.

Second row magic

In a post on Weibo, Tesla Vice President for China Grace Tao described the upcoming Model Y L as a “full-scene 6-seat luxury SUV.” This description, particularly the executive’s “full-scene” description, is notable, with Tesla China watchers such as @zhongwen2005 stating that “full-scene” typically means that all seats can be folded flat.

If Tesla is able to design the Model Y L’s second row seats to fold flat, it would provide the extended wheelbase vehicle with a lot more utility than typical six-seaters, including the six-seat Model X. And considering that the Model Y L will likely be priced just above the standard Model Y, its price would likely be extremely competitive, even in challenging markets such as China. 

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