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

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4 years ago

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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. 

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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. 

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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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Tesla launches new Model S and Model X, and the changes are slim

Tesla’s newest versions of its flagship vehicles have arrived with some slim changes.

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5 hours ago

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June 12, 2025

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Credit: Tesla

Tesla has officially launched the newest versions of its flagship Model S and Model X vehicles, but the changes are pretty slim, which is something we expected when a couple cars were spotted during public testing recently.

The new “refreshed” Model S and Model X were spotted recently by The Kilowatts, and the changes appeared to be a new front camera, a new color, and only a handful of other changes.

Tesla officially announced the launch of the Model S and Model X on Thursday night, and here’s what it listed as the changes to the two vehicles:

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  • Frost Blue paint color
  • Up to 410 miles of range (Model S Long Range – our longest range Tesla yet)
  • Even quieter inside: less wind + road noise & more effective Active Noise Cancellation
  • New wheel designs & improved aerodynamics = more range
  • Front fascia camera for better visibility
  • Dynamic ambient lighting that brings unique animations along the dash & doors upon entry
  • An even smoother ride thanks to new bushings & suspension design
  • Adaptive driving beams
  • New exterior styling for Model S Plaid, optimized for high-speed stability
  • More space for 3rd row occupants & cargo (Model X)

We expected most of these changes, especially the new Frost Blue paint color, as it was spotted by The Kilowatts in its initial coverage of the cars being spotted a few weeks back. Here’s what it looks like officially:

Some of the changes are familiar from the Model Y Refresh, which featured the quieter interior through acoustic-lined glass, a front fascia camera, new bushings, and suspension improvements for a smoother ride.

However, Tesla did refine the Model S Plaid’s exterior for “optimized high-speed stability.” You can see the difference between the two below:

The front-end air diffusers are much deeper, and the front end is more boxy than the previous iteration of the Plaid Model S.

Here are some more images of the Model S that Tesla released in a teaser video:

Tesla sells such a low volume of the Model S and Model X that it was probably less than likely that the company would put endless manpower and effort into completely redesigning it. CEO Elon Musk said a few years ago that the two cars would only stay in production for “sentimental reasons.” 

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While they are very special to the Tesla family, they are not incredibly important to the mission of the company.

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Tesla owners across the globe prepare for Robotaxi launch with this neat customization

Tesla will eventually have Robotaxis worldwide. Some owners are already preparing.

Published

5 hours ago

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June 12, 2025

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Credit: @HanChulYong | X

Tesla owners are already preparing for the company’s launch of the Robotaxi platform with a new, neat customization that is appearing around the world.

On Tuesday, the first Tesla Robotaxi test mule was spotted in Austin, where the company will launch the first driverless rides of this ride-hailing service. At first, it will be a limited rollout, reserved for a select few. CEO Elon Musk said public rides could occur as soon as June 22.

First Tesla driverless robotaxi spotted in the wild in Austin, TX

However, the Tesla Robotaxi platform is not one that will be confined to cities and geofenced to certain areas.

Eventually, Tesla will gain enough confidence to roll the Full Self-Driving software straight to every car in the customer fleet that paid for it. Owners will be able to generate income for themselves while they sleep, as the cars will operate as ride-hailing vehicles for people to use for transportation.

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In an effort to prepare for the launch of Robotaxi, Tesla owners across the globe are installing Tesla’s ‘Robotaxi’ word art on their cars.

Here’s one in South Korea:

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Here’s another in the U.S.:

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Obviously, this is more of a symbol of support for the Robotaxi launch, but many owners are recognizing that Tesla’s Full Self-Driving software will extend to them the ability to use their personal cars as ride-hailing vehicles, becoming a part of the global fleet of self-driving chauffeurs.

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Tesla sues former Optimus engineer for stealing trade secrets

Tesla is suing a former engineer who worked on Optimus after he left and immediately started a robotics company that achieved quick development of a hand.

Published

13 hours ago

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June 12, 2025

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Credit: Elon Musk | X

Tesla is suing former Optimus engineer Jay Li in federal court after accusing him of stealing trade secrets and using them to enable a startup he founded after he left.

Li is accused of stealing confidential files and using them to help get his company, “Proception,” off to a rocking start. Tesla says the files Li took helped his new startup “shortcut the typical development process” for robot hands, something that took Tesla years to develop and evolve.

The company said in the complaint (via Reuters):

“Through Li’s pilfering, Defendant Proception purportedly achieved in a matter of months what it has taken Tesla over four years, hundreds of employees, and billions of dollars to achieve.”

Li was an employee at Tesla for several years, working on the Optimus sensor team from 2022 to 2024. The company says it utilized and devoted “extraordinary resources” to the development of Optimus, which has come a long way since its unveiling several years ago.

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Tesla Optimus to receive hands with 22 degrees of freedom later this year

Li allegedly downloaded confidential files related to Optimus’ robotic hand movement research before departing the company. He did not work on the hands at the time. However, he left and swiftly started Proception, as the suit states the company was founded just six days after he left Tesla.

Proception was gloating about its ability to build robotic hands just five months after the company was founded. Tesla says the hands have “striking similarities” to its own design for Optimus.

The company is looking for monetary damages and a court order that would block Proception from misusing the secrets it accuses Li of taking.

This is not the first suit Tesla has filed over trade secrets and confidential information theft. Recently, it accused German-Canadian dual citizen Klaus Pflugbeil of stealing battery-related secrets. He was arrested and sentenced to two years in prison.

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Men accused of selling Tesla battery secrets arrested in undercover sting

The U.S. Department of Justice used an undercover sting to arrest Pflugbeil.

Tesla is being represented by Josh Krevitt, Orin Snyder, and Angelique Kaounis of Gibson Dunn & Crutcher.

The case is Tesla Inc. v. Perception Inc., U.S. District Court for the Northern District of California, No. 5:25-cv-04963.

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