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Tesla giga casting gets its biggest supporter yet from legacy auto

Credit: Idea Group/YouTube

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During Toyota’s announcement earlier this week, the veteran Japanese automaker announced that it was adopting “giga casting” systems for its upcoming electric vehicles. Similar to Tesla, Toyota intends to produce the car body from three main components in a modular structure, allowing for “significant component integration.”  

“On the manufacturing axis, the car body will be constructed from three main components in a new modular structure. Adopting giga casting will allow significant component integration, which contributes to the reduction of vehicle development costs and factory investment,” Toyota noted.

The use of giga casting was pioneered by Tesla with the Model Y crossover. It involves the use of house-sized machines that are able to produce aluminum parts that are significantly bigger than anything traditionally used in auto manufacturing. With the system in place, a piece such as the Model Y’s rear underbody could be made with one piece instead of dozens. 

This system, analysts have estimated, has likely helped Tesla achieve industry-leading profitability

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In what appears to be yet another nod to Tesla’s futuristic factories, Toyota also stated that it plans to implement a “self-propelling” assembly line, where vehicles that are being produced would essentially drive themselves through the manufacturing process. That’s an ambitious goal, and one that would likely require a lot of investment from the automaker. 

While giga casting presents a lot of advantages, it also comes with its own set of challenges. The giga casting machines are extremely expensive, so they are great for companies like Tesla, which only produces a few models. For automakers like Toyota, which would likely offer a variety of next-generation electric cars, the investments required for giga casting would likely be more substantial. Vehicles made with giga casted parts are also expected to be more difficult to repair in the event of an accident.

Giga casting machines are produced by a number of companies, such as IDRA, which makes Tesla’s machines. IDRA has been a unit of China’s LK Industries since 2008. Other giga press makers include the Buhler Group, Shibaura Machine, Yizumi, and Haitian. 

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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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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Microsoft partners with Starlink to expand rural internet access worldwide

The update was shared ahead of Mobile World Congress.

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Credit: Starlink/X

Microsoft has announced a new collaboration with Starlink as part of its expanding digital access strategy, following the company’s claim that it has extended internet connectivity coverage to more than 299 million people worldwide.

The update was shared ahead of Mobile World Congress, where Microsoft detailed how it surpassed its original goal of bringing internet access to 250 million people by the end of 2025.

In a blog post, Microsoft confirmed that it is now working with Starlink to expand connectivity in rural and hard-to-reach regions.

“Through our collaboration with Starlink, Microsoft is combining low-Earth orbit satellite connectivity with community-based deployment models and local ecosystem partnerships,” the company wrote.

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The partnership is designed to complement Microsoft’s existing work with local internet providers and infrastructure companies across Africa, Latin America, and India, among other areas. Microsoft noted that traditional infrastructure alone cannot meet demand in some regions, making low-Earth orbit satellite connectivity an important addition.

Kenya was cited as an early example. Working with Starlink and local provider Mawingu Networks, Microsoft is supporting connectivity for 450 community hubs in rural and underserved areas. These hubs include farmer cooperatives, aggregation centers, and digital access facilities intended to support agricultural productivity and AI-enabled services.

Microsoft stated that 2.2 billion people globally remain offline, and that connectivity gaps risk widening as AI adoption accelerates.

Starlink’s expanding constellation, now numbering more than 9,700 satellites in orbit, provides near-global coverage, making it one of the few systems capable of delivering broadband to remote regions without relying on terrestrial infrastructure. 

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Starlink is expected to grow even more in the coming years as well, especially as SpaceX transitions its fleet to Starship, which is capable of carrying significantly larger payloads compared to its current workhorse, the Falcon 9.

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Tesla expands US LFP battery supply with LG Energy Solution deal: report

The report was initially published by TheElec, citing industry sources.

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Credit: Tesla

LG Energy Solution (LGES) will manufacture lithium iron phosphate (LFP) energy storage system (ESS) batteries for Tesla at its Lansing, Michigan facility. 

The report was initially published by TheElec, citing industry sources.

LG Energy Solution’s Lansing plant, formerly known as Ultium Cells 3, was previously operated as a joint venture with General Motors. LGES acquired GM’s stake in May 2025 and now fully owns the site. With a production capacity of 50 GWh per year, it is one of the company’s largest facilities in North America.

LG Energy Solution is converting part of the Lansing factory to produce LFP batteries for energy storage systems. Equipment orders for the new lines have already been placed, and mass production is reportedly expected to begin in the second half of next year.

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Last July, LG Energy Solution disclosed a 5.94 trillion won battery supply agreement running from August 2027 to July 2030. While the company did not name the customer, industry sources pointed to Tesla as the buyer.

Tesla has primarily used CATL’s prismatic batteries for its Megapack systems. The move to source prismatic LFP cells from LG Energy Solution’s U.S. plant could then be seen as part of Tesla’s efforts to bolster its North American supply base for its energy storage business.

For the Lansing conversion, LG Energy Solution reportedly plans to use electrode equipment originally ordered under its Ultium Cells venture with General Motors. Suppliers reportedly include CIS and Hirano Tecseed for electrode systems, TSI for mixing equipment, CK Solution for heat exhaust systems, A-Pro for formation equipment, and Shinjin Mtech for assembly kits.

Tesla currently manufactures energy storage products at facilities in California and Shanghai, though another Megafactory that produces the Megapack is also expected to be built in Texas. As per recent reports, the Texas Megafactory recently advanced with a major property sale.

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Tesla begins Grok AI chatbot rollout to Australia and New Zealand fleet

The update follows earlier deployments in the United States and Europe.

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Credit: Tesla

Tesla has rolled out its Grok AI assistant to Australia and New Zealand, embedding the conversational chatbot directly into compatible vehicles via an over-the-air update. 

The system, developed by Elon Musk’s xAI, is now live on select models, giving drivers access to a voice-based assistant that goes well beyond traditional command-driven controls.

The update follows earlier deployments in the United States and Europe.

Tesla Australia confirmed Grok is available on Model S, Model 3, Model X and Model Y vehicles equipped with an AMD processor and running software version 2025.26 or later.

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“Grok is coming to Teslas in Australia and New Zealand. It can answer almost any question using real-time information & also add/edit navigation destinations to become your personal guide. Phased rollout has now begun to eligible vehicles,” Tesla Australia and New Zealand wrote in a post on its official X account.

Drivers can activate Grok using the steering wheel controls once the update is installed. Access requires either a Premium Connectivity subscription or a stable Wi-Fi connection.

Unlike conventional in-car voice assistants that rely on fixed prompts, Grok is designed to respond conversationally. It can adjust navigation mid-trip, locate nearby points of interest, explain dashboard warnings, provide driving guidance and reference the owner’s manual. 

Tesla noted that interactions with Grok are processed by xAI and remain anonymous to Tesla, adding that conversations are not linked to a specific driver or vehicle.

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Grok has attracted attention overseas for offering multiple interaction modes. In the U.S., users can select personalities such as Assistant, Language Tutor, Therapist, Storyteller and Meditation. Additional optional modes for adult users include settings labeled Unhinged, Motivation, Argumentative, Romantic and even Sexy.

Viral clips shared online have shown Grok adopting sarcastic or playful tones that differ from more neutral digital assistants, with the AI assistant typically catching drivers off-guard with its sharp personality and wit. 

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