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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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Tesla has landed a massive deal to expand its charging infrastructure for heavy-duty electric trucks — and not just theirs, but all manufacturers.
Tesla entered an agreement with Pilot Travel Centers, the largest operator of travel centers in the United States. Tesla’s Semi Chargers, which are used to charge Class 8 electric trucks, will be responsible for providing energy to various vehicles from a variety of manufacturers.
The first sites are expected to open later this Summer, and will be built at select locations along I-5 and I-10, major routes for commercial vehicles and significant logistics companies. The chargers will be available in California, Georgia, Nevada, New Mexico, and Texas.
Each station will have between four and eight chargers, delivering up to 1.2 megawatts of power at each stall.
The project is the latest in Tesla’s plans to expand Semi Charging availability. The effort is being put forth to create more opportunities for the development of sustainable logistics.
Senior Vice President of Alternative Fuels at Pilot, Shannon Sturgil, said:
“Helping to shape the future of energy is a strategic pillar in meeting the needs of our guests and the North American transportation industry. Heavy-duty charging is yet another extension of our exploration into alternative fuel offerings, and we’re happy to partner with a leader in the space that provides turnkey solutions and deploys them quickly.”
Tesla currently has 46 public Semi Charger sites in progress or planned across the United States, mostly positioned along major trucking routes and industrial areas. Perhaps the biggest bottleneck with owning an EV early on was charging availability, and that is no different with electric Class 8 trucks. They simply need an area to charge.
Tesla is spearheading the effort to expand Semicharging availability, and the latest partnership with Pilot shows the company has allies in the program.
The company plans to build 50,000 units of the Tesla Semi in the coming years, and with early adopters like PepsiCo, DHL, and others already contributing millions of miles of data, fleets are going to need reliable public charging.
🚨 Pilot working with Tesla to install and expand Semi Chargers is a perfect example of two industry leaders working together for the greater good.
As more commerce companies expand into EVs, Semi Charger will be more commonly available for electrified fleets, making efforts… pic.twitter.com/VPLIYyq15b
— TESLARATI (@Teslarati) January 27, 2026
Tesla is partnering with other companies for the development of the Semi program, most notably, a conglomeration with Uber was announced last year.
Tesla lands new partnership with Uber as Semi takes center stage
The ride-sharing platform plans to launch the Dedicated EV Fleet Accelerator Program, which it calls a “first-of-its-kind buyer’s program designed to make electric freight more affordable and accessible by addressing key adoption barriers.”
The Semi is one of several projects that will take Tesla into a completely different realm. Along with Optimus and its growing Energy division, the Semi will expand Tesla to new heights, and its prioritization of charging infrastructure.
Elon Musk
Elon Musk’s Boring Company opens Vegas Loop’s newest station
The Fontainebleau is the latest resort on the Las Vegas Strip to embrace the tunneling startup’s underground transportation system.
Elon Musk’s tunneling startup, The Boring Company, has welcomed its newest Vegas Loop station at the Fontainebleau Las Vegas.
The Fontainebleau is the latest resort on the Las Vegas Strip to embrace the tunneling startup’s underground transportation system.
Fontainebleau Loop station
The new Vegas Loop station is located on level V-1 of the Fontainebleau’s south valet area, as noted in a report from the Las Vegas Review-Journal. According to the resort, guests will be able to travel free of charge to the stations serving the Las Vegas Convention Center, as well as to Loop stations in Encore and Westgate.
The Fontainebleau station connects to the Riviera Station, which is located in the northwest parking lot of the convention center’s West Hall. From there, passengers will be able to access the greater Vegas Loop.
Vegas Loop expansion
In December, The Boring Company began offering Vegas Loop rides to and from Harry Reid International Airport. Those trips include a limited above-ground segment, following approval from the Nevada Transportation Authority to allow surface street travel tied to Loop operations.
Under the approval, airport rides are limited to no more than four miles of surface street travel, and each trip must include a tunnel segment. The Vegas Loop currently includes more than 10 miles of tunnels. From this number, about four miles of tunnels are operational.
The Boring Company President Steve Davis previously told the Review-Journal that the University Center Loop segment, which is currently under construction, is expected to open in the first quarter of 2026. That extension would allow Loop vehicles to travel beneath Paradise Road between the convention center and the airport, with a planned station located just north of Tropicana Avenue.
News
Tesla leases new 108k-sq ft R&D facility near Fremont Factory
The lease adds to Tesla’s presence near its primary California manufacturing hub as the company continues investing in autonomy and artificial intelligence.
Tesla has expanded its footprint near its Fremont Factory by leasing a 108,000-square-foot R&D facility in the East Bay.
The lease adds to Tesla’s presence near its primary California manufacturing hub as the company continues investing in autonomy and artificial intelligence.
A new Fremont lease
Tesla will occupy the entire building at 45401 Research Ave. in Fremont, as per real estate services firm Colliers. The transaction stands as the second-largest R&D lease of the fourth quarter, trailing only a roughly 115,000-square-foot transaction by Figure AI in San Jose.
As noted in a Silicon Valley Business Journal report, Tesla’s new Fremont lease was completed with landlord Lincoln Property Co., which owns the facility. Colliers stated that Tesla’s Fremont expansion reflects continued demand from established technology companies that are seeking space for engineering, testing, and specialized manufacturing.
Tesla has not disclosed which of its business units will be occupying the building, though Colliers has described the property as suitable for office and R&D functions. Tesla has not issued a comment about its new Fremont lease as of writing.
AI investments
Silicon Valley remains a key region for automakers as vehicles increasingly rely on software, artificial intelligence, and advanced electronics. Erin Keating, senior director of economics and industry insights at Cox Automotive, has stated that Tesla is among the most aggressive auto companies when it comes to software-driven vehicle development.
Other automakers have also expanded their presence in the area. Rivian operates an autonomy and core technology hub in Palo Alto, while GM maintains an AI center of excellence in Mountain View. Toyota is also relocating its software and autonomy unit to a newly upgraded property in Santa Clara.
Despite these expansions, Colliers has noted that Silicon Valley posted nearly 444,000 square feet of net occupancy losses in Q4 2025, pushing overall vacancy to 11.2%.
Tesla lands massive deal to expand charging for heavy-duty electric trucks
Elon Musk’s Boring Company opens Vegas Loop’s newest station
