Tesla is closing in on a new, groundbreaking manufacturing technique, according to a new report. The process is similar to the company’s industry-disrupting casting technique that saw it eliminate many parts into several pieces. However, this takes efficient manufacturing a step further.
Tesla has used casting for a few years to streamline manufacturing, improve vehicle engineering and safety, and revolutionize how cars are built. The Model Y truly broke the barrier of how cars are made, and the numerous teardowns we saw of the all-electric crossover showed Tesla had made significant progress in its vehicle manufacturing techniques.
But a new report from Reuters takes it a step further. Citing “five people familiar with the move,” the report claims Tesla is looking to install even larger giga-casting machines that would have 16,000 tons or more of clamping power.
This would not only require new machines but also new factories that are large enough to house them.
The machines would be responsible for producing a single large frame that would combine the front and rear sections with a middle underbody, which is where the battery is housed.
This would also be the design that is used for the upcoming $25,000 model:
“The five people said a single large frame – combining the front and rear sections with the middle underbody where the battery is housed – could be used in Tesla’s small EV which it aims to launch with a price tag of $25,000 by the middle of the decade.”
In order to enable a fluid manufacturing process where molds can be slightly adjusted or tweaked during the design process, Tesla is looking to stay away from traditional techniques. Large casting structures have been seen as “prohibitive,” according to the report. Although they are efficient, the potential adjustments are too much of a risk.
So Tesla is thinking outside the box and turned to firms that can make the test molds out of materials that would allow for adjustments after they are built. These firms specialize in making molds out of industrial sand with 3D printers.
The biggest advantage is not the tweaking of prototypes because printing can be done in a matter of hours, it is the cost. It is only 3% of doing the same thing with a metal prototype.
Nevertheless, there are disadvantages as well. They may not offer the same crashworthiness that Tesla expects out of its vehicles, as aluminum alloys, which would be used in this new technique, behaved differently in sand and metal molds.
Casting specialists overcame this hurdle by fine-tuning the molten alloy cooling process and after-production heat treatment.
Tesla still has yet to make a final decision on this technique, according to the report. The big obstacle with this process is the fact that they need larger factories, which it is already in the process of doing with Mexico in the works, and potential factories in India also coming to the table.
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Tesla China’s domestic sales fell 4.8% in 2025, but it’s not doom and gloom
Despite the full-year dip, Tesla finished the year with record domestic sales in December.
Tesla posted 625,698 retail vehicle sales in China in 2025, marking a 4.8% year-on-year decline as the EV maker navigated an increasingly competitive EV market and a major production transition for its best-selling vehicle.
Despite the full-year dip, Tesla finished the year with record domestic sales in December.
Retail sales slip amid Model Y transition
Tesla’s 2025 retail sales in China were down from 657,102 units in 2024, when the company ranked third in the country’s new energy vehicle (NEV) market with a 6.0% share. In 2025, Tesla’s share slipped to 4.9%, placing it fifth overall, as noted in a CNEV Post report.
Part of the decline seemed tied to operational disruptions early in the year. Tesla implemented a changeover to the new Tesla Model Y in the first quarter of 2025, which required temporary production pauses at Giga Shanghai. That downtime reduced vehicle availability early during the year, weighing on the company’s retail volumes in China and in areas supplied by Giga Shanghai’s exports.
China remained one of Tesla’s largest markets, accounting for 38.24% of its global deliveries of 1.64 million vehicles in 2025. However, the company also saw exports from Giga Shanghai fall to 226,034 units, down nearly 13% year-on-year. It remains to be seen how much of this could be attributed to the Model Y changeover and how much could be attributed to other factors.
Strong December 2025 finish
While the full-year picture showed some contraction, Tesla closed 2025 on a high note. According to data from the China Passenger Car Association (CPCA), Tesla China delivered a record 93,843 vehicles domestically in China in December, its highest monthly total ever. That figure was up 13.2% from a year earlier and 28.3% higher than November.
The surge was driven in part by Tesla prioritizing domestic deliveries late in the year, allowing buyers to lock in favorable purchase tax policies. In December alone, Tesla captured 7.0% of China’s NEV market and a notable 12.0% share of the country’s battery-electric segment.
On a wholesale basis, Tesla China sold 851,732 vehicles in 2025, down 7.1% year-on-year. From this number, 97,171 were from December 2025 alone. Tesla Model 3 wholesale figures reached 312,738 units, a year-over-year decrease of 13.12%. The Tesla Model Y’s wholesale figures for 2025 were 538,994 units, down 3.18% year-over-year.
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Tesla Robovan’s likely first real-world use teased by Boring Company President
As per the executive, the vehicle will be used to move large crowds through Las Vegas during major events.
The Boring Company President Steve Davis has shared the most likely first real-world use for Tesla’s Robovan.
As per the executive, the vehicle will be used to move large crowds through Las Vegas during major events.
Tesla Robovan for high-demand events
During a feature with the Las Vegas Review-Journal, Boring Company President Steve Davis stated that the Tesla Robovan will be used in Sin City once the Vegas Loop expands across the Strip and downtown and the fleet grows to about 1,200 Teslas.
At that scale, Robovans would primarily be deployed during predictable surges, such as game days and large shows, when many riders are traveling to the same destination at the same time.
“The second you have four (passengers) and you have to start stopping, the best thing you can do is put your smallest vehicle in, which is a car. But if you know people are going to the stadium because of a game, you’ll know an hour before, two hours before, that a lot of people are going to a game or a Sphere show, if you are smart about it, that’s when you put a high occupancy vehicle in, that’s when you put the Robovan in,” Davis said.
Vegas Loop expansion
Steve Davis’s Robovan comment comes amid The Boring Company’s efforts to expand the Vegas Loop’s airport service. Phase 1 of rides to Harry Reid International Airport began last month, allowing passengers to travel from existing Loop stations such as Resorts World, Encore, Westgate, and the Las Vegas Convention Center.
Phase 2 will add a 2.2-mile dual-direction tunnel from Westgate to Paradise Road. That section is expected to open within months and will allow speeds of up to 60 mph on parts of the route, while expanding the fleet to around 160 vehicles.
Future phases are expected to extend tunnels closer to airport terminals and add multiple stations along University Center Drive. At this point, the system’s fleet is expected to grow close to 300 Teslas. The final phase, an underground airport station, was described by Davis as the system’s “holy grail.” This, however, has no definite timeframe as of yet.
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Tesla seeks engineer to make its iOS Robotaxi app feel “magical”
It appears that Tesla is hard at work in ensuring that users of its Robotaxi service are provided with the best user experience possible.
Tesla is hiring an iOS Engineer for its Robotaxi app team, with the job posting emphasizing the creation of polished experiences that make the service not just functional, but “magical.”
Needless to say, it appears that Tesla is hard at work in ensuring that users of its Robotaxi service are provided with the best user experience possible.
Robotaxi App features
As observed by Tesla community members, Tesla has gone live with a job listing for an iOS Engineer for its Robotaxi App. The job listing mentions the development of a “core mobile experience that enables customers to summon, track, and interact with a driverless vehicle. From requesting a ride to enabling frictionless entry, from trip planning to real-time vehicle status and media control.”
Interestingly enough, the job listing also mentioned the creation of polished experiences that make the Robotaxi more than just functional. “You will take full ownership of features—from architecture design to robust implementation—delivering delightful and polished experiences that make Robotaxi not just functional, but magical,” Tesla noted in its job listing.
Apple’s “magical” marketing
Tesla’s use of the word “magical” when referring to the Robotaxi app mirrors the marketing used by Apple for some of its key products. Apple typically uses the word when referring to products or solutions that transform complex technology into something that feels effortless, simple, and natural to daily life. Products such as the AirPods’ seamless pairing with the iPhone and FaceID’s complex yet simple-to-use security system have received Apple’s “magical” branding.
With this in mind, Tesla seems intent on developing a Robotaxi app that is sophisticated, but still very easy to use. Tesla already has extensive experience in this area, with the Tesla App consistently being hailed by users as one of the best in its segment. If Tesla succeeds in making the Robotaxi app worthy of its “magical” branding, then it wouldn’t be a surprise if the service sees rapid adoption even among mainstream consumers.
Tesla China’s domestic sales fell 4.8% in 2025, but it’s not doom and gloom
Tesla Robovan’s likely first real-world use teased by Boring Company President
