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Tesla files to expand Fremont factory, make Model Y ‘tent’ permanent
Tesla has filed an application with the City of Fremont to expand its vehicle production facility by 64,000 square feet. The application describes plans to implement foundations and install below-ground utilities under General Assembly 4.5 (GA 4.5), where the Model Y production lines are located at the Fremont factory.
GA 4.5 is currently a tent, or spring structure, that sits outside of Tesla’s Fremont factory. It has been home to the Model Y production and possibly the Model 3 as well since February 2020. According to past permit filings with the City of Fremont’s local government, Tesla initially opened the tent outside during this time and has added to the tent on several occasions.
Tesla’s General Assembly 4.5 line at the Fremont Factory. (Credit: Ryan Ferrin | YouTube)
Tesla is now looking to make GA 4.5 permanent by adding a 64,000 square foot structure onto the Fremont factory. The spring structure that was used before was erected in a pinch as Tesla was planning to begin the production of the Model Y but didn’t have the space for it with Model S, Model X, and Model 3 production all going on under the same roof.
The filing, known as BLD2021-05126, also called Foundations for GA 4.5 South Expansion, states:
“Foundations and underground utilities for proposed 64,000 sf south expansion.”
Credit: City of Fremont
Tesla will add GA 4.5 to the Southern portion of the Fremont factory, expanding the factory itself, and at the same time, making the 4.5 assembly lines permanent with foundational structures and underground plumbing and electrical work.
It seems that it was only a matter of time before Tesla expanded the Fremont factory to make way for more projects. While demand continues to expand globally, Tesla is still funneling many of its vehicles from the Fremont factory in Northern California. The plant handles global Model S and Model X demand, while Model 3 demand is split with Giga Shanghai. Some Model 3s from Fremont have made their way to other countries that aren’t in North America, but it seems that Giga Shanghai is taking some of the load, especially in the European market.
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Here is my understanding of the general assembly lines at Fremont:
• GA1/2 Model S/X (GA1&2 merged into a single line)
• GA3 Model 3
• GA4 Model 3 or Y (tent)
• GA4.5 Model 3 or Y (tent, under construction)
• GA5 Model 3 or Y (indoors next to GA1&2, under construction)— Troy Teslike (@TroyTeslike) July 5, 2020
Last year, Tesla expanded the Model Y production lines to make way for the IDRA Giga Press. This was filed in July 2020, and the Giga Press is now operational at the facility and is cranking out single-piece rear castings for the Model Y crossover. Tesla attempted to expand GA 4.5 in April but had to solve issues with stormwater drainage before the project was ultimately approved.
The Fremont factory has been in Tesla’s possession since 2010 after the company purchased it from Toyota’s New United Motor Manufacturing, Inc. The first Model S rolled off the lines at Fremont in 2012, and the company has made numerous improvements to the facility since being in its possession. The expansion of the facility to make GA 4.5 permanent will alleviate space constraints, allowing Tesla to build more of its all-electric vehicles for a constantly growing and expanding consumer base.
Tesla didn’t immediately respond to Teslarati’s inquiry about the expansion.
Here’s a recent flyover of the Fremont Factory by Gabeincal.
Just hours after Starship Flight 13 achieved a successful soft splashdown of its upper stage in the Indian Ocean on July 24, Elon Musk announced an ambitious next step for the company’s next launch of the rocket.
“Unless we discover problems after mission data review, SpaceX will attempt to catch the ship with the tower on [the] next flight,” the SpaceX CEO posted on X on Friday.
That “next flight” is expected to be Flight 14. The plan involves returning the Starship upper stage, commonly called the “ship,” to the Starbase launch tower in Texas and catching it mid-air using the same mechanical “chopsticks” arms that have already proven themselves with the Super Heavy booster.
Unless we discover problems after mission data review, SpaceX will attempt to catch the ship with the tower on next flight
— Elon Musk (@elonmusk) July 25, 2026
A successful catch would mark the first time an orbital-class upper stage has been recovered this way, advancing SpaceX’s goal of full and rapid reusability for the entire vehicle.
SpaceX has already demonstrated the tower-catch technique multiple times with Super Heavy. The first successful catch came on Flight 5 in October 2024, when Booster 12 was plucked from the sky by the Mechazilla arms. Subsequent flights, including those involving Boosters 14 and 15, repeated the feat. Several of those recovered boosters were later inspected, refurbished, and flown again, proving the system’s viability for quick turnaround.
Traditional reusable rockets, such as SpaceX’s own Falcon 9 or Blue Origin’s New Shepard, land on legs either on land or droneships. Rocket Lab has recovered its small Electron first stages by helicopter, but those are far lighter vehicles.
SpaceX Starship just nailed something it’s never done before
The China Academy of Launch Vehicle Technology (CALT), a subsidiary of the China Aerospace Science and Technology Corp. (CASC), completed a catch of its booster on July 10. They are the only entity besides SpaceX to attempt and complete the feat.
Flight 13 provided encouraging data. The ship executed a controlled reentry, flipped, and soft-landed intact in the ocean after deploying Starlink satellites, offering the first clear post-splashdown views of an undamaged heat shield. The Super Heavy booster, meanwhile, experienced a harder splashdown in the Gulf of Mexico.
Musk has previously stressed that ship catches would only follow multiple successful soft ocean landings to minimize risk of debris over land.
If Flight 14 succeeds, SpaceX would take a major stride toward routine, rapid reuse of both stages—critical for lowering launch costs and supporting ambitious plans for lunar and Mars missions. For now, teams are reviewing the Flight 13 data. Should everything check out, the next Starship flight could deliver one of the most spectacular recoveries in aerospace history.
In a move echoing its earlier commitment to open innovation, Tesla CEO Elon Musk announced recently that the company plans to make the design and software of its Model S and Model X fully open source.
This follows the same approach Tesla took with its original Roadster, releasing all available design, engineering, and diagnostic materials in November 2023 so that “whatever we have, you now have.”
Just as Tesla made the original Roadster design & software open source, we plan to do the same with Model S & X
— Elon Musk (@elonmusk) July 24, 2026
The Model S, introduced in 2012, was Tesla’s first mass-produced vehicle and a groundbreaking luxury electric sedan. It offered impressive range, rapid acceleration, and over-the-air software updates that redefined expectations for electric cars.
The Model X, launched in 2015, built on that foundation as a high-performance electric SUV notable for its distinctive falcon-wing doors, spacious interior, and advanced safety features. Both models served as flagships that helped establish Tesla as a leader in the EV industry and popularized long-range battery-electric vehicles.
Production of the Model S and Model X was wound down earlier in 2026, with manufacturing ending in the second quarter. Tesla redirected the Fremont factory space previously used for these vehicles toward higher-priority projects, including Optimus humanoid robots and the Cybercab autonomous vehicle.
By the time of Musk’s open-source announcement, custom orders had closed and only remaining inventory was available.
Open-sourcing the designs and software offers several clear advantages. Owners of these aging but still capable vehicles gain better access to technical documentation, diagnostic tools, and software resources, making independent repairs and modifications easier and more affordable.
Independent repair shops and third-party specialists can support the large existing fleet without relying solely on Tesla’s service network. Enthusiasts and engineers can study real-world implementations of Tesla’s battery, powertrain, and software systems, potentially accelerating broader industry progress in electric mobility.
The step aligns with Tesla’s 2014 patent pledge and its overall mission to advance sustainable transport by sharing hard-won knowledge rather than locking it behind proprietary walls.
By releasing these materials now that the models have left production, Tesla ensures continued support for its early adopters while freeing internal resources for future technologies. The open-source release of the original Roadster already enabled simulations, community projects, and deeper technical understanding.
Extending that practice to the Model S and Model X should deliver similar benefits on a larger scale, helping keep these influential vehicles relevant and repairable for years to come
Tesla flexed one incredible Robotaxi metric during the Q2 Earnings Call that skeptics have to hate to hear. The company’s platform has already driven more than 380,000 miles of unsupervised ride-hailing across several states with no notable incidents.
During the company’s Q2 Earnings Call on Wednesday, Vice President of AI, Ashok Elluswamy, said:
“First of all, I’d like to state that the Robotaxi program has been operating extremely well. Especially in terms of safety, the program has had an impeccable safety record. We have driven more than 380,000 miles of unsupervised Robotaxi, now across six cities in two different states. We have had zero notable incidents. Any reports have been of other actors impacting us when we were stationary. I like to emphasize how safe the operation has been so far. Zero notable incidents over 380,000 miles.”
Elluswamy’s claim over Robotaxi miles is a significant milestone for Tesla in the grand scheme, especially considering this is a sizeable number of miles without any incident.
0 notable incidents across over 380,000 miles traveled by Robotaxi
— Tesla (@Tesla) July 22, 2026
Tesla’s self-driving approach is much different than that of other companies. Tesla has maintained that vision is the only thing needed to have a solid and effective self-driving suite. Many self-driving companies utilize things like LiDAR, sensors, and other elements to improve performance, but Elluswamy sent a jab at those who believe it’s needed.
“Historically, the so-called experts have always claimed that you need LiDARs, radars, HD maps, and the entire kitchen sink to drive safely. Here we show that such is not true. You can have safe, comfortable, and affordable autonomy with just cameras. This record should be a huge validation of Tesla’s entire AI approach.”
The feat of accumulating this many miles without any driver behind the wheel is impressive. The thing is, Tesla is also doing this across several different locations, with varying traffic rules, pedestrian levels, weather patterns, and other important factors.
While Tesla is not ready to roll out an unsupervised platform completely, it is a slow but steady indication that the company is well on its way to figuring things out.
The company’s attitude toward expansion is slow, safe, and controlled, and despite this huge milestone, it will still be some time until we see Tesla truly unleash unsupervised rides more aggressively.
SpaceX wants to catch Starship for launch 14, Elon Musk says
Tesla to open source Model S and Model X designs and software
