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Tesla Model 3 gets Full Self-Driving HW3 upgrade: Full details with lessons learned

(Credit: Tesla Joy/Twitter)

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True to Elon Musk’s expectations on Twitter last month, it appears that Tesla is now looking to ramp Hardware 3 retrofits for owners who purchased the Full Self-Driving suite and whose cars are equipped with HW2 or HW2.5. A recent account involving a Tesla owner-enthusiast’s experience with her Model 3’s HW3 upgrade shows that there are still some areas in the retrofit process that can be improved. 

Tesla Model 3 owner-enthusiast TeslaJoy was looking to do a video on the company’s recent voice command update when she noticed that the feature on her vehicle was not working properly. This prompted her to make an appointment with Tesla to get her car checked in and fixed. During the troubleshooting process, she inquired if a possible HW3 retrofit could be done to her vehicle as well. Fortunately, a HW3 unit was available for her Model 3, and so, a rather eventful upgrade process began. 

Tesla Service Centers currently receive batches of HW3 units from the electric car maker, and each unit is assigned to a specific VIN. This is the reason why for now, at least, owners are not advised to call Tesla to schedule a HW3 retrofit. Fortunately for Joy, the Tesla Service Center opted to perform the HW3 upgrade at the same time as her appointment, since she would need to bring her Model 3 back for a retrofit anyway.

(Credit: TeslaJoy/Twitter)

Since the retrofit was estimated to take around 5 hours, Tesla asked the Model 3 owner to leave her car for the day and claim it the next business day. That was December 31, which meant that the vehicle should be ready the day after New Year’s. As it would turn out, the Service Center would end up encountering difficulties installing the necessary firmware on Joy’s Model 3. This resulted in delays, which culminated in the vehicle’s HW3 retrofit being completed on January 5, 2020, over five days after the Model 3 owner turned in her car. 

Hardware 3 retrofits are available for owners who have purchased Tesla’s Full Self-Driving suite, and whose cars are still equipped with the company’s HW2 and HW2.5 units. With Hardware 3 installed, owners will be able to utilize the full suite of FSD capabilities that the company is rolling out today. One of these is the FSD preview that Tesla rolled out for the holidays, as well as features like traffic cone recognition. 

True to Elon Musk’s words on Twitter, the HW3 retrofit is free for owners who have purchased the company’s FSD suite. Joy, for her part, was able to get FSD last March at a discounted price of $2,000 on top of her Enhanced Autopilot. FSD currently costs $7,000 when it is included in a new vehicle’s order. 

Based on Joy’s experience, it appears that owners should expect to wait some time for their vehicles are set to be retrofitted. In the Model 3 owner’s case, her car’s upgrade ended up taking days since the first HW3 kit that was installed did not function properly. This resulted in the vehicle essentially getting retrofitted twice, causing delays. Tesla did give Joy a $500 Uber voucher due to the absence of loaner vehicles, but the whole experience showed notable points for improvement nonetheless. 

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In a way, TeslaJoy‘s experience with her Model 3’s HW3 retrofit stands in stark contrast with the experiences of Model S owner Sofiaan Fraval, whose car was upgraded by a Service Center during a voluntary HEPA replacement. In Fraval’s case, his Model S was fully retrofitted within a matter of hours, and it was calibrated in pretty much the same day. A Tesla Model S owner who runs the Electric Dreams YouTube channel also received his vehicle’s HW3 retrofit without any issues, and it was performed by a mobile technician, not a Service Center. 

In the Electric Dreams host’s case, the entire HW3 retrofit was conducted from the convenience of his home, with a mobile service tech coming over in the morning, taking an hour and a half for the installation to be completed, and an additional two hours for the necessary firmware to be loaded onto the vehicle. This is in line with Elon Musk’s previous statement on Twitter, where he stated that HW3 retrofits should be possible through Tesla’s mobile service fleet

Overall, there seems to be a variance with regards to the experience of owners when getting their vehicles retrofitted with Tesla’s FSD computer. Some owners seem to be experiencing a seamless, painless process, while some, like Joy, end up having to test their patience. Hopefully, as Tesla ramps its HW3 retrofits this quarter, the company could work in optimizing its upgrade process, so there are more experiences like the Electric Dreams host’s, and less like TeslaJoy‘s. 

Watch TeslaJoy‘s HW3 experience in the video below. 

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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