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Tesla’s Gigafactory formula rose from a humble “tent” at the Fremont Factory
Back in 2018, Tesla was in a very different place. The company was struggling to release the Model 3, and it was behind on Elon Musk’s aggressive self-imposed vehicle production targets. The Fremont Factory’s assembly lines were not producing enough Model 3s, and it seemed like the company was poised to fail. Critics and shorts circled Tesla like sharks smelling blood in the water. But something unexpected happened, and things were never the same after.
Throwing convention out the window, Tesla built another Model 3 line inside a massive sprung structure at the Fremont Factory grounds, which CEO Elon Musk fondly called a “tent” online. The structure, dubbed as GA4, was mocked to the highest degree, used as a joke by critics, and dismissed outright by skeptics. However, what was almost unknown at the time was that Tesla might have actually stumbled into something special with its sprung structure-based line. By building a simple, straight, Model 3 line inside a “tent,” Tesla seems to have effectively created a solid Gigafactory formula.
No standard automotive solution could be built in time, so we created a new solution. It is working & has slightly higher quality than the more traditional general assembly line. Perhaps most surprising is that the total cost of production in the Sprung tent is lower.
— Elon Musk (@elonmusk) June 27, 2018
A Practical Concept
The sprung structure-based Model 3 line was the brainchild of Automotive President Jerome Guillen, widely known as Elon Musk’s “problem solver” back in the Model S’ early days. The “tent”-based line followed a relatively simple system, with vehicles being assembled progressively the further they moved into the tent. Even GA4’s loading bays were placed on the sides of the structure, allowing Tesla to take deliveries into the line efficiently. Musk was enthusiastic about the sprung structure on Twitter, noting not long after the “tent” was built that the vehicles produced in the site had “slightly higher quality” than cars made elsewhere.
These humble but creative beginnings appear to have become the heart of Tesla’s Gigafactory formula, one used in Giga Shanghai and Giga Berlin, and seemingly improved further with Gigafactory Texas. This could be seen in the design and processes that Tesla has adopted so far in its Shanghai and Berlin plants, both of which invoke the image of a scaled-up, refined, and optimized version of Fremont’s “tent.”
A Gigafactory Formula
Tesla critics typically overlook the fact that the Fremont Factory is a legacy car plant at its core. It’s an expansive facility, and it is impressive in its own right, but it’s not a site developed specifically to produce all-electric cars. Thus, for the Model S, Model X, and the Model 3’s early days, Tesla was essentially developing a system that makes EVs at scale using a facility designed initially to manufacture cars equipped with the internal combustion engine.
Of course, Tesla has made numerous adjustments to make the Fremont Factory into one of the most advanced electric vehicle plants in the market. However, it is difficult not to be impressed with Tesla’s quick production ramp and flexibility in Gigafactory Shanghai, arguably the first EV factory that the company built using its GA4 formula, with its simple production lines to its numerous loading bays at its side. This concept seems to have been carried over to Gigafactory Berlin, which is expected to ramp its operations at a rate that rivals even that of Giga Shanghai.
A Matter of Scale
Ultimately, it appears that GA4 was Tesla’s “eureka” moment of sorts, at least for its electric vehicle factories. By scaling up and refining the sprung structure-based concept, Tesla was able to create monster factories like Giga Shanghai, and later this year, Gigafactory Berlin as well. However, this is not all as Tesla seems to be adopting an updated design for Gigafactory Texas, with its three main buildings built parallel with each other. Little is known about the reasons behind Giga Texas’ design, but there’s little doubt that the expansive facility will be very impressive when completed nonetheless.
Prior to the Model 3’s “production hell,” Elon Musk spoke about Tesla’s “Alien Dreadnought” factories, which are supposed to be so automated and advanced that they would resemble alien facilities featured in sci-fi fiction. Tesla seems to have shelved this idea following the Model 3’s challenges in its initial production ramp. With an established Gigafactory formula of sorts in its repertoire, however, and coupled with innovations such as the Model Y’s megacasts, Elon Musk’s dreadnoughts may not be too far into the future at all.
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Elon Musk
Elon Musk to attend 2026 World Economic Forum at Davos
The Tesla CEO was confirmed as a last-minute speaker for a session with BlackRock CEO Larry Fink.
Elon Musk is poised to attend the 2026 World Economic Forum in Davos. The Tesla CEO was confirmed as a last-minute speaker for a session with BlackRock CEO Larry Fink, signaling a thaw in Musk’s long-strained relationship with the event.
A late addition
Organizers of the World Economic Forum confirmed that Elon Musk was added shortly before the event to a Thursday afternoon session, where he was scheduled to speak with Fink, as noted in a Bloomberg News report. Musk’s upcoming appearance marks Musk’s first participation in the forum, which annually draws political leaders, business executives, and global media to Davos, Switzerland.
Musk’s attendance represents a departure from his past stance toward the event. He had been invited in prior years but declined to attend, including in 2024. His upcoming appearance followed remarks from his political ally, Donald Trump, who addressed the forum earlier in the week with a wide-ranging speech.
A previously strained relationship
Musk had frequently criticized the World Economic Forum in the past, describing it as elitist and questioning its influence. In earlier posts, he characterized the gathering as “boring” and accused it of functioning like an unelected global authority. Those remarks contributed to a long-running distance between Musk and WEF organizers.
The forum previously said Musk had not been invited since 2015, though that position has since shifted. Organizers indicated last year that Musk was welcome amid heightened interest in his political and business activities, including his involvement in the Trump administration’s Department of Government Efficiency (DOGE). Musk later stepped away from that role.
Despite his friction with the World Economic Forum, Musk has remained central to several global events, from SpaceX’s provision of satellite internet services in geopolitically sensitive regions through Starlink to the growing use of xAI’s Grok in U.S. government applications.
News
Tesla states Giga Berlin workforce is stable, rejects media report
As per the electric vehicle maker, production and employment levels at the facility remain stable.
Tesla Germany has denied recent reports alleging that it has significantly reduced staffing at Gigafactory Berlin. As per the electric vehicle maker, production and employment levels at the facility remain stable.
Tesla denies Giga Berlin job cuts report
On Wednesday, German publication Handelsblatt reported that Tesla’s workforce in Gigafactory Berlin had been reduced by about 1,700 since 2024, a 14% drop. The publication cited internal documents as its source for its report.
In a statement to Reuters, Tesla Germany stated that there has been no significant reduction in permanent staff at its Gigafactory in Grünheide compared with 2024, and that there are no plans to curb production or cut jobs at the facility.
“Compared to 2024, there has been no significant reduction in the number of permanent staff. Nor are there any such plans. Compared to 2024, there has been no significant reduction in the number of permanent staff. Nor are there any such plans,” Tesla noted in an emailed statement.
Tesla Germany also noted that it’s “completely normal” for a facility like Giga Berlin to see fluctuations in its headcount.
A likely explanation
There might be a pretty good reason why Giga Berlin reduced its headcount in 2024. As highlighted by industry watcher Alex Voigt, in April of that year, Elon Musk reduced Tesla’s global workforce by more than 10% as part of an effort to lower costs and improve productivity. At the time, several notable executives departed the company, and the Supercharger team was culled.
As with Tesla’s other factories worldwide, Giga Berlin adjusted staffing during that period as well. This could suggest that a substantial number of the 1,700 employees reported by Handelsblatt were likely part of the workers who were let go by Elon Musk during Tesla’s last major workforce reduction.
In contrast to claims of contraction, Tesla has repeatedly signaled plans to expand production capacity in Germany. Giga Berlin factory manager André Thierig has stated on several occasions that the site is expected to increase output in 2026, reinforcing the idea that the facility’s long-term trajectory remains growth-oriented.
Elon Musk got a brash response from Ryanair CEO Michael O’Leary, who said in a press conference on Wednesday afternoon that the Tesla frontman’s criticism of the airline not equipping Starlink has increased bookings for the next few months.
The two have had a continuing feud over the past several weeks after Musk criticized the airline for not using Starlink for its flights, which would enable fast, free, and reliable Wi-Fi on its aircraft.
Tesla CEO Elon Musk trolls budget airline after it refuses Starlink on its planes
Musk said earlier this week that he was entertaining the idea of purchasing Ryanair and putting someone named Ryan in charge, which would oust O’Leary from his position.
However, the barbs continued today, as O’Leary held a press conference, aiming to dispel any beliefs about Starlink and its use case for Ryanair flights, which are typically short in length.
O’Leary said in the press conference today:
“The Starlink people believe that 90% of our passengers would happily pay for wifi access. Our experience tells us less than 10% would pay; He (Elon) called me a retar*ed twat. He would have to join the back of a very, very long queue of people that already think I’m a retar*ed twat, including my four teenage children.”
He then went on to say that, due to Musk’s publicity, bookings for Ryanair flights have increased over the past few days, up 2 to 3 percent:
“But we do want to thank him for the wonderful boost in publicity. Our bookings are up 2-3% in the last few days. So thank you to Mr. Musk, but he’s wrong on the fuel drag. Non-European citizens cannot own a majority of European airlines, but if he wants to invest in Ryanair, we think it would be a very good investment.”
O’Leary didn’t end there, as he called Musk’s social media platform X a “cesspit,” and said he has no concern over becoming a member of it. However, Ryanair has been very active on X for several years, gaining notoriety for being comical and lighthearted.
🚨 Ryanair CEO’s comments on X and Starlink today at the planned presser.
Strange comments here, it just feels like it’s time to end all this crap https://t.co/NYeG95bM82
— TESLARATI (@Teslarati) January 21, 2026
The public spat between the two has definitely benefited Ryanair, and many are calling for it to end, especially those who support Musk, as they see it as a distraction.
Nevertheless, it is likely going to end with no real movement either way, and is more than likely just a bit of hilarity between the two parties that will end in the coming days.
Elon Musk to attend 2026 World Economic Forum at Davos
Tesla states Giga Berlin workforce is stable, rejects media report
