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Tesla Gigacasting to make BEV production cheaper than gas by 2027

Credit: Idea Group/YouTube

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Battery-electric vehicles (BEVs) could become cheaper to produce than gas cars within the next few years, in part due to Tesla Gigacasting techniques, as one research firm suggests.

In a press release shared on Thursday, research firm Gartner said it believes the upcoming generation of BEVs will be cheaper to produce on average than vehicles with internal combustion engines (ICEs) by 2027. The news comes as many automakers are working to produce higher-volume, lower-cost BEVs in the coming years, with technology like Tesla’s Gigacasting techniques paving the way for cheaper production efforts.

“New OEM incumbents want to heavily redefine the status quo in automotive,” said Pedro Pacheco, Gartner’s VP of Research. “They brought new innovations that simplify production costs such as centralized vehicle architecture or the introduction of Gigacastings that help reduce manufacturing cost and assembly time, which legacy automakers had no choice to adopt to survive.”

The firm also expects production costs to drop more quickly than battery costs, ultimately resulting in BEVs reaching price parity more quickly than expected.

“This means BEVs will reach ICE cost parity much faster than initially expected, but at the same time, it will make some repairs of BEVs considerably costlier,” Pacheco added.

Tesla VP of Public Policy and Business Development Rohan Patel responded to the note on Saturday, noting how cheap the sticker prices on Tesla’s vehicles have become—especially when leasing.

“Today (not 2027), you can lease a Tesla Model 3 for $329/month and a Model Y for $379/month,” Patel wrote on X.

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Because of the soon-widespread use of new technology in production, Gartner predicts that the average cost of EV battery and serious accident repairs will increase by around 30 percent in the same timeframe. The firm adds that this could have other effects, such as more total write-offs following collisions and potentially even higher insurance premiums or refusal of coverage for certain kinds of vehicles.

The firm also predicts that as many as 15 percent of the electric vehicle (EV) makers founded in the last decade will either go bankrupt or be bought out by 2027, as market competition continues to increase with more options for consumers.

“This does not mean the EV sector is crumbling,” Pacheco said. “It is simply entering a new phase where companies with the best products and services will win over the remaining.”

Gartner expects EV shipments to reach 18.4 million units this year, increasing to 20.6 million units in 2025. However, it also says the market is shifting from the “gold rush” era of EVs to “survival of the fittest,” as governed by automakers’ abilities to meet early EV adopters’ needs.

EVs to increase almost tenfold by 2030 under current policies: IEA

What are your thoughts? Let me know at zach@teslarati.com, find me on X at @zacharyvisconti, or send your tips to us at tips@teslarati.com.

Zach is a renewable energy reporter who has been covering electric vehicles since 2020. He grew up in Fremont, California, and he currently lives in Colorado. His work has appeared in the Chicago Tribune, KRON4 San Francisco, FOX31 Denver, InsideEVs, CleanTechnica, and many other publications. When he isn't covering Tesla or other EV companies, you can find him writing and performing music, drinking a good cup of coffee, or hanging out with his cats, Banks and Freddie. Reach out at zach@teslarati.com, find him on X at @zacharyvisconti, or send us tips at tips@teslarati.com.

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Tesla hiring Body Fit Technicians for Cybercab’s end of line

As per Tesla’s Careers website, Body Fit Technicians for the Cybercab focus on precision body fitment work, including alignment, gap and flush adjustments.

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Credit: Tesla/X

Tesla has posted job openings for Body Fit Technicians for the Cybercab’s end-of-line assembly, an apparent indication that preparations for the vehicle’s initial production are accelerating at Giga Texas. 

Body Fit Technicians for Cybercab line

As per Tesla’s Careers website, Body Fit Technicians for the Cybercab focus on precision body fitment work, including alignment, gap and flush adjustments, and certification of body assemblies to specification standards. 

Employees selected for the role will collaborate with engineering and quality teams to diagnose and correct fitment and performance issues and handle detailed inspections, among other tasks.

The listing noted that candidates should be experienced with automotive body fit techniques and comfortable with physically demanding tasks such as lifting, bending, walking, and using both hand and power tools. The position is based in Austin, Texas, where Tesla’s main Cybercab production infrastructure is being built.

Cybercab poised for April production

Tesla CEO Elon Musk recently reiterated that the Cybercab is still expected to start initial production this coming April. So far, numerous Cybercab test units have been spotted across the United States, and recent posts from the official Tesla Robotaxi account have revealed that winter tests in Alaska for the autonomous two-seater are underway. 

While April has been confirmed as the date for the Cybercab’s initial production, Elon Musk has also set expectations about the vehicle’s volumes in its initial months. As per the CEO, the Cybercab’s production will follow a typical S-curve, which means that early production rates for the vehicle will be very limited. 

“Initial production is always very slow and follows an S-curve. The speed of production ramp is inversely proportionate to how many new parts and steps there are. For Cybercab and Optimus, almost everything is new, so the early production rate will be agonizingly slow, but eventually end up being insanely fast,” Musk wrote in a post on X.

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Swedish unions consider police report over Tesla Megapack Supercharger

The Tesla Megapack Supercharger opened shortly before Christmas in Arlandastad, outside Stockholm.

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Credit: Tesla Charging/X

Swedish labor unions are considering whether to file a police report related to a newly opened Tesla Megapack Supercharger near Stockholm, citing questions about how electricity is supplied to the site. The matter has also been referred to Sweden’s energy regulator.

Tesla Megapack Supercharger

The Tesla Megapack Supercharger opened shortly before Christmas in Arlandastad, outside Stockholm. Unlike traditional charging stations, the site is powered by an on-site Megapack battery rather than a direct grid connection. Typical grid connections for Tesla charging sites in Sweden have seen challenges for nearly two years due to union blockades.

Swedish labor union IF Metall has submitted a report to the Energy Market Inspectorate, asking the authority to assess whether electricity supplied to the battery system meets regulatory requirements, as noted in a report from Dagens Arbete (DA). The Tesla Megapack on the site is charged using electricity supplied by a local company, though the specific provider has not been publicly identified.

Peter Lydell, an ombudsman at IF Metall, issued a comment about the Tesla Megapack Supercharger. “The legislation states that only companies that engage in electricity trading may supply electricity to other parties. You may not supply electricity without a permit, then you are engaging in illegal electricity trading. That is why we have reported this… This is about a company that helps Tesla circumvent the conflict measures that exist. It is clear that it is troublesome and it can also have consequences,” Lydell said.

Police report under consideration

The Swedish Electricians’ Association has also examined the Tesla Megapack Supercharger and documented its power setup. As per materials submitted to the Energy Market Inspectorate, electrical cables were reportedly routed from a property located approximately 500 meters from the charging site.

Tomas Jansson, ombudsman and deputy head of negotiations at the Swedish Electricians’ Association, stated that the union was assessing whether to file a police report related to the Tesla Megapack Supercharger. He also confirmed that the electricians’ union was coordinating with IF Metall about the matter. “We have a close collaboration with IF Metall, and we are currently investigating this. We support IF Metall in their fight for fair conditions at Tesla,” Jansson said.

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Tesla HW4.5 spotted in new Model Y, triggers speculation

Owners taking delivery of recent Model Y builds have identified components labeled “AP45.”

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Credit: Tesla

Tesla’s Hardware 4.5 computer appears to have surfaced in newly delivered Model Y vehicles, prompting fresh speculation about an interim upgrade ahead of the company’s upcoming AI5 chip.

Owners taking delivery of recent Model Y builds have identified components labeled “AP45,” suggesting Tesla may have quietly started rolling out revised autonomy hardware.

Hardware 4.5 appears in new Model Y units

The potential Hardware 4.5 sighting was first reported by Model Y owner @Eric5un, who shared details of a Fremont-built 2026 Model Y AWD Premium delivered this January. As per the Model Y owner, the vehicle includes a new front camera housing and a 16-inch center display, along with an Autopilot computer labeled “AP45” and part number 2261336-02-A.

The Tesla owner later explained that he confirmed the part number by briefly pulling down the upper carpet liner below the Model Y’s glovebox. Other owners soon reported similar findings. One Model Y Performance owner noted that their December build also appeared to include Hardware 4.5, while another owner of an Austin-built Model Y Performance reported spotting the same “AP45” hardware.

These sightings suggest that Tesla may already be installing revised FSD computers in its new Model Y batches, despite the company not yet making any formal announcements about Hardware 4.5.

What Hardware 4.5 could represent

Clues about Hardware 4.5 have surfaced previously in Tesla’s Electronic Parts Catalog. As reported by NotATeslaApp, the catalog has listed a component described as “CAR COMPUTER – LEFT HAND DRIVE – PROVISIONED – HARDWARE 4.5.” The component, which features the part number 2261336-S2-A, is priced at $2,300.00.

Longtime Tesla hacker @greentheonly has noted that Tesla software has contained references to a possible three-SoC architecture for some time. Previous generations of Tesla’s FSD computer, including Hardware 3 and Hardware 4, use a dual-SoC design for redundancy. A three-SoC layout could allow for higher inference throughput and improved fault tolerance.

Such an architecture could also serve as a bridge to AI5, Tesla’s next-generation autonomy chip expected to enter production later in 2026. As Tesla’s neural networks grow larger and more computationally demanding, Hardware 4.5 may provide additional headroom for vehicles built before AI5 becomes widely available.

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