Connect with us

News

Tesla’s Gigafactory formula rose from a humble “tent” at the Fremont Factory

Published

on

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. 

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. 

Advertisement

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.”

Tesla’s Gigafactory Shanghai. (Credit: Tesla)

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.  

Tesla Gigafactory Texas’s parallel buildings envisioned. (Credit: Joe Tegtmeyer/YouTube)

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. 

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

Advertisement

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.

Advertisement
Comments

News

Tesla rolling out Robotaxi pilot in SF Bay Area this weekend: report

Similar to the Austin pilot, the Robotaxi rides will reportedly be a paid service.

Published

on

Credit: @AdanGuajardo/X

Tesla is reportedly preparing to launch a Robotaxi pilot program in the Bay Area this weekend, with invites to a select number of customers reportedly being sent out as early as this Friday.

The update was shared in a report from Insider, which cited an internal memo from the electric vehicle maker.

New Robotaxi service launch

According to Insider, the Robotaxi service in the Bay Area is set to launch as soon as Friday. Thus, some Tesla owners in the area should receive invites to use the driverless ride-hailing service. Similar to the Austin pilot, the Robotaxi rides will reportedly be a paid service.

The publication noted that the Robotaxi service’s geofence in its Bay Area launch will be quite large, as it will include Marin, much of the East Bay, San Francisco, and San Jose. This is not surprising as California has long been saturated with Teslas, and it is home to several of the electric vehicle maker’s key facilities.

Unlike the Austin pilot, the Tesla Robotaxi service’s pilot in the Bay Area will use safety drivers seated in the driver’s seat. These drivers will be able to manually take over using the steering wheel and brakes as needed. As per a spokesperson from the California DMV, the agency recently met with Tesla but the company is yet to submit a formal application to operate fully driverless cars. 

Advertisement

Tesla Robotaxi expansion

Interestingly enough, Tesla did tease the release of its Robotaxi service to the Bay Area in its second quarter earnings call. While discussing the service, Tesla VP of Autopilot/AI Software Ashok Elluswamy mentioned that the company will initially be rolling out Robotaxis with safety drivers in the San Francisco Bay Area. He did, however, also highlight that the electric vehicle maker is working hard to get government permission to release the service for consumers.

“The next thing to expand would be in the San Francisco Bay Area. We are working with the government to get approval here and, in the meanwhile, launch the service without the person in the driver seat just to expedite and while we wait for regulatory approval,” he stated.

Continue Reading

News

Tesla is ready with a perfect counter to the end of US EV tax credits

Tesla executives have mentioned that these more affordable models would resemble the company’s current lineup.

Published

on

Credit: Tesla Asia/X

The United States’ electric vehicle tax credit is coming to an end at the end of the third quarter. Tesla, the country’s leading electric vehicle maker, is ready to meet this challenge with a rather simple but clever counter. 

Tesla executives outlined this strategy in the recently held Q2 2025 earnings call.

End of the US EV tax credit

While Elon Musk has always maintained that he prefers a market with no EV tax credit, he also emphasized that he supports the rollback of any incentives given to the oil and gas industry. The Trump administration has not done this so far, instead focusing on the expiration of the $7,500 EV tax credit at the end of the third quarter.

Tesla has been going all-in on encouraging customers to purchase their vehicles in Q3 to take advantage of lower prices. The company has also implemented a series of incentives across all its offerings, from the Cybertruck to the Model 3. This, however, is not all, as the company seems to be preparing a longer-term solution to the expiration of the EV tax credit.

Affordable variants

During the Q2 2025 earnings call, Vice President of Vehicle Engineering Lars Moray stated that Tesla really did start the production of more affordable models in June. Quality builds of these vehicles are being ramped this quarter, with the goal of optimizing production over the remaining months of the year. If Tesla is successful, these models will be available for everyone in Q4. 

Advertisement

“We started production in June, and we’re ramping quality builds and things around the quarter. And given that we started in North America and our goal is to maximize production with a higher rate. So starting Q3, we’re going to keep pushing hard on our current models to avoid complexity… We’ll be ready with new, more affordable models available for everyone in Q4.,” Moravy stated. 

These comments suggest that Tesla should be able to offer vehicles that are competitively priced even after the EV tax credit has been phased out. Interestingly enough, previous comments from Tesla executives have mentioned that these more affordable models would resemble the company’s current lineup. This suggests that the more affordable models may indeed be variations of the Model Y and Model 3, but offered at a lower price.

Continue Reading

Elon Musk

Elon Musk reveals Tesla’s next Robotaxi expansion in more ways than one

Tesla Robotaxi is growing in more ways than one. Tesla wants to expand and hopes to reach half the U.S. population by the end of the year.

Published

on

Credit: Tesla

Tesla CEO Elon Musk revealed the company’s plans for its next expansion of the Robotaxi in terms of both the geofence in Austin and the platform overall, as it looks to move to new areas outside of Texas.

Tesla launched the Robotaxi platform last month on June 22, and has since expanded both the pool of users and the area that the driverless Model Y vehicles can travel within.

The first expansion of the geofence caught the attention of nearly everyone and became a huge headline as Tesla picked a very interesting shape for the new geofence, resembling male reproductive parts.

The next expansion will likely absolve this shape. Musk revealed last night that the new geofence will be “well in excess of what competitors are doing,” and it could happen “hopefully in a week or two.”

Musk’s full quote regarding the expansion of the geofence and the timing was:

“As some may have noted, we have already expanded our service area in Austin. It’s bigger and longer, and it’s going to get even bigger and longer. We are expecting to greatly increase the service area to well in excess of what competitors are doing, hopefully in a week or two.”

The expansion will not stop there, either. As Tesla has operated the Robotaxi platform in Austin for the past month, it has been working with regulators in other areas, like California, Arizona, Nevada, and Florida, to get the driverless ride-hailing system activated in more U.S. states.

Tesla confirmed that they are in talks with each of these states regarding the potential expansion of Robotaxi.

Musk added:

“As we get the approvals and prove out safety, we will be launching the autonomous ride-hailing across most of the country. I think we will probably have autonomous ride-hailing in probably half the population of the US by the end of the year.”

We know that Tesla and Musk have been prone to aggressive and sometimes outlandish timelines regarding self-driving technology specifically. Regulatory approvals could happen by the end of the year in several areas, and working on these large metros is the best way to reach half of the U.S. population.

Tesla said its expansion of the geofence in Austin is conservative and controlled due to its obsession with safety, even admitting at one point during the Earnings Call that they are being “paranoid.” Expanding the geofence is necessary, but Tesla realizes any significant mistake by Robotaxi could take it back to square one.

Continue Reading

Trending