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Tesla’s Elon Musk explains why too much electric vehicle range does not make sense
Elon Musk commented last night that Tesla could have had a Model S that was capable of 600 miles of range on a single charge. However, Tesla decided not to pursue the what would be an industry-leading metric, because it would impact handling, efficiency, and overall performance negatively.
“We could’ve made a 600 mile Model S 12 months ago, but that would’ve made the product worse imo, as 99.9% of time you’d be carrying unneeded battery mass, which makes acceleration, handling & efficiency worse,” Musk said in a reply to Whole Mars Blog, who stated Lucid may have been the first to deliver a 500-mile EV, but Tesla would be the first to produce it. “Even our 400+ mile range car is more than almost anyone will use,” the Tesla CEO added.
We could’ve made a 600 mile Model S 12 months ago, but that would’ve made the product worse imo, as 99.9% of time you’d be carrying unneeded battery mass, which makes acceleration, handling & efficiency worse. Even our 400+ mile range car is more than almost anyone will use.
— Elon Musk (@elonmusk) March 2, 2022
The battle of alleviating range anxiety amongst new electric vehicle owners is something that will eventually subside altogether. However, there are entirely too many people who still bring up concerns of where they will be able to charge their cars, arguing that gas stations are on every corner but EV chargers are not. While this is true, EV chargers are more available than many may think. In even rural South Central Pennsylvania (where I live), there are about seventeen EV chargers, including an eight-stall Tesla Supercharger. All are within ten miles of my house.
Even still, the concerns of how much range is enough still circulate through the community of prospective EV buyers. Everything will require sacrifice. And while most passenger gas cars can travel around 400 miles on a full tank of gas, ABC News says the average American only travels sixteen miles per day for work. U.S. Census data suggests Americans spend around 27.6 minutes driving to work one way. Hundreds of miles of range are not completely necessary.
As Musk also said, more range usually means more batteries, which adds to mass and takes away from the fun driving experience that EVs have been commended for. The Tesla Model S has 375 miles of range, and at one time had over 400 miles of range. The Model S Long Range Plus had 402 miles of range, and one of the primary reasons was “significant mass reduction.”
“Mass is the enemy of both efficiency and performance, and minimizing the weight of every component is an ongoing goal for our design and engineering teams,” Tesla said in a blog post announcing the 400-mile Model S in June 2020. “Several lessons from the engineering design and manufacturing of Model 3 and Model Y have now been carried over to Model S and Model X. This has unlocked new areas of mass reduction while maintaining the premium feel and performance of both vehicles. Additional weight savings have also been achieved through the standardization of Tesla’s in-house seat manufacturing and lighter weight materials used in our battery pack and drive units.”
Structural Battery Pack
Tesla’s Structural Battery Pack compartmentalizes the idea that mass distribution can be used in an advantageous way. During Battery Day in September 2020, Musk outlined the ideas for the Tesla Structural Pack, and how it was designed.
“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 density of the pack not only increases structural rigidity and safety, but it also improves mass and range by strategically placing cells in areas where they would compliment the vehicle.
Credit: Tesla
What about Tesla’s planned more than 400-mile range vehicles
Interestingly, Tesla has several vehicles on the way that feature range estimations of over 400 miles. The Cybertruck’s Tri-Motor powertrain, which may take a backseat to the rumored Quad-Motor variant, had a 500+ mile range rating when Tesla still had the configurator for the vehicle available. With the new 4680 battery, Tesla’s vehicles will likely be able to reach the 400-mile threshold without sacrificing too much of the performance or efficiency that Musk spoke of.
The next-gen Roadster, which has sat on Tesla’s backburner for several years, also has an incredible range estimation of 600+ miles. The Roadster may be a special exception to the range rule, but with the astronomical expectations for the vehicle, including the ability to hover, excessive battery weight may take away from the Roadster’s 1.1-second acceleration from 0-60 and its handling due to its small, sporty frame.
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A California radiologist who drove his Tesla Model Y off a 250-foot cliff in an attempt to kill his family has had his charges dismissed after doctors say he is “doing well” in a mental health program.
Dharmesh Patel was charged with three counts of attempted murder in connection with a January 2023 crash where he drove his Tesla off a cliff, injuring his wife and two children, aged 7 and 4 at the time.
Patel drove the Tesla off Devil’s Slide in California, an area that is extremely rough to the point that investigators and rescuers expected the worst when arriving at the scene for the first time. Patel supposedly had schizoaffective disorder, according to Deputy District Attorney Dominique Davis.
Shockingly, Patel’s wife, who was in the vehicle, testified that she did not want her husband to be prosecuted, noting that their children missed their father and they wanted him to come back home. Patel’s attorney argued, “not everyone who commits a crime is a criminal.”
Doctor who took Tesla off cliff gets support from unlikely person
A three-day trial in Mental Health Diversion Court ruled in Patel’s favor, which kept him out of jail and instead on house arrest. He was admitted to a Mental Health Diversion Program, which he successfully completed, the Associated Press reported. San Mateo County District Attorney Steve Wagstaffe said the judge was “required by law” to dismiss the charges:
“If the person who’s given mental health diversion follows the treatment plan, there’s nothing that can be done, and at the end of the two years he gets it wiped out of his record.”
Wagstaffe said he has argued, along with other DAs in California, to have attempted murder removed from the list of charges eligible to be dismissed due to mental health diversion programs.
Patel had the charges officially dismissed on Monday; his wife waited for him as he left court and they departed the building together, according to Mercury News. Patel surrendered his California medical license in December.
The crash has been one of the best examples of Tesla’s incredible engineering, which has saved four lives in this particular instance. The car was totalled but kept the four human beings alive and safe, which is something that many referred to as “an absolute miracle.”
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Radiologist who drove Tesla off cliff has attempted murder charges dismissed
Tesla battery recycling efforts increased 20 percent last year
