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Tesla is gathering the pieces for an Alien Dreadnought 2.0 attempt at Fremont

The Tesla Model Y body shop in Fremont, CA. (Credit: Tesla)

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Recent construction permits filed for the Fremont Factory suggest that Tesla is looking to improve the massive electric vehicle production facility’s automation even further. With the plant’s ongoing improvements, it almost seems like Tesla is about to attempt yet another crack at Elon Musk’s once-failed initiative: the “Alien Dreadnought” factory.

The Fremont factory has caught the attention of the nation in the past weeks, as Elon Musk and Tesla locked horns with officials from Alameda County who insisted that the facility remain shut even after California moved to its Stage 2 response for the ongoing pandemic. After a lawsuit, an act of bold defiance from the CEO, some strong words from a CA Assemblywoman against Musk, and support coming from both sides of the political spectrum, the plant was finally allowed to formally return to its normal operations.

But even during the shutdown, Tesla has been exhibiting signs that it intends to improve the Fremont factory. Permits for paint shop improvements were filed, for example, and similar documents were submitted for upgrades in the facility’s vehicle production lines. These lines were speculated to be allotted for Model Y production, which would allow the company to produce the all-electric crossover en masse without any issues.

The Tesla Fremont factory. (Credit: Tesla)

Just recently, Tesla also filed building permit applications for the addition of “MINO robot riser anchorage structural package” and “MINO Equipment and fixture anchorage” for the Fremont Factory. These may seem a bit understated, though a look at MINO’s expertise provides a notable hint at what Tesla may be planning for its main EV production facility in the United States.

MINO Automation is a firm that provides fully integrated automation production systems that are tailor-fit for its clients. As per the company’s website, MINO specializes in Body in White (BIW) manufacturing systems that concentrate on body framing, laser application, sealing, hemming, resistance welding, and automated stranger systems. MINO works with FANUC Robotics as well, which are also being utilized by Tesla.

(Credit: Fremont.gov)

A look at Tesla’s recent building permit applications for the Fremont factory shows that the electric car maker is set on improving its plant, and it is also doing what it can to raise its automated processes. Just as Elon Musk intended during the Model 3’s initial delivery event, more automation would likely result in a smooth production ramp. This, of course, is especially important with the Model Y, Tesla’s highest-volume EV to date.

Those who have followed Tesla over the years would know that the company had already attempted an extremely-automated vehicle production approach in the past. Dubbed as Elon Musk’s “Alien Dreadnought” initiative, the program, which was intended for the Model 3, was supposed to be Tesla’s big breakthrough for vehicle production.

Alas, history would show that this was not meant to be, as issues with the over-automated line eventually forced Tesla to adopt a more human-centered approach to Model 3 manufacturing. Even Elon Musk eventually stated that humans are ultimately “underrated.”

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(Credit: Fremont.gov)

But Tesla today is not the same as the company as it was during the early days of the Model 3’s production ramp. Today, Tesla is an experienced mass-manufacturer of electric cars, having produced thousands upon thousands of Model 3 sedans last year. And the company is nowhere near done. Over in Shanghai, Tesla China is attempting to ramp its local Model 3 production at a pace that far exceeds the company’s operations in Fremont.

With this in mind, there seems to be no better time to attempt yet another crack at a hyper-automated factory than today. The Model Y is the perfect vehicle for such an initiative, considering that the crossover is a high-volume car that’s designed to be built in a simple and efficient manner. As per the findings of automotive teardown specialist Sandy Munro, the Model Y seems to be designed for automation, from its rigid wiring systems that are friendly to robots, to its giant casts that eliminate unnecessary parts.

Time will tell if Elon Musk and Tesla are going to attempt another Alien Dreadnought for the Fremont factory. But either way, the remaining months of the year will likely see the California-based electric car production facility manufacturing vehicles at a volume that has never been witnessed before.

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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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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