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 FSD mocks BMW human driver: Saves pedestrian from near miss
Tesla FSD anticipated a BMW driver’s lane drift before the human behind the wheel could react.
A video posted to r/TeslaFSD this week put a sharp spotlight on Tesla’s Full Self-Driving (FSD) software being able to react to pedestrian intent than an actual human driver behind the wheel. In the Reddit clip, a BMW driver can be seen rolling through a neighborhood street completely unaware of a pedestrian stepping in to cross. At the same time, a Tesla driving on FSD had already begun slowing down before the pedestrian even began their attempt to cross the street The BMW kept moving, prompting the pedestrian to hop back, while the Tesla came to a stop and provide right-of-way for the human to safely cross.
That gap between what the BMW driver saw and what FSD had already processed is the story. Tesla FSD wasn’t reacting to a person in the street, rather it was reading the signals that a person was about to enter it based on the pedestrian’s movement, trajectory, and their trajectory to telegraph intent.
Tesla’s FSD is now built on an end-to-end neural network trained on billions of real-world miles, learning to interpret subtle human behavioral cues the same way an experienced human driver does instinctively. The difference is consistency. A human driver distracted for two seconds misses what FSD does not.
Tesla sues California DMV over Autopilot and FSD advertising ruling
Reddit commenters in the thread were blunt about the BMW driver’s failure, with several pointing out that the pedestrian was visible well before the crossing. One response put it plainly that the car on FSD saw the situation developing before the human in the other car had registered there was a situation at all.
Tesla has published data showing FSD (Supervised) is 54% safer than a human driver, accumulated across billions of miles driven on the system. Elon Musk has said FSD v14 will outperform human drivers by a factor of two to three, and that v15 has “a shot” at a 10x improvement. Pedestrian safety is where the stakes are highest, and where intent prediction closes the gap fastest. At 30 mph, a car covers roughly 44 feet per second. An extra second of awareness from reading a person’s body language rather than waiting for them to step out is often the difference between a near miss and a fatality.
Video and community discussion: r/TeslaFSD on Reddit
FSD saves man from becoming a pancake. BMW driver nearly flattens him.
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News
Tesla Robotaxi gets a small but significant change
In the world of Tesla, where billion-dollar battery breakthroughs and autonomy milestones dominate headlines, a quiet design update can still pack a punch.
In the world of Tesla, where billion-dollar battery breakthroughs and autonomy milestones dominate headlines, a quiet design update can still pack a punch.
Last week in downtown Austin, sharp-eyed observers spotted a subtle but telling evolution on the Cybercab: a new “ROBOTAXI” logo graphic now graces the vehicle’s doors at Tesla’s Autonomy Popup.
What looks at first glance like a minor stylistic choice is, in fact, a deliberate rebranding move that hints at how the company envisions its robotaxi fleet fitting into everyday life.
The updated lettering is bold, graffiti-inspired, and unapologetically street-smart. Rendered in black with dripping white accents and a glowing yellow outline, the font evokes urban energy and playful irreverence.
Live From Downtown Austin:
Tesla Cybercab with new logo Graphic at their Autonomy Popup pic.twitter.com/MTTb9KDr3b
— David Moss (@DavidMoss) March 13, 2026
Gone is the sleek, minimalist typography that defined earlier Cybercab prototypes. In its place is something more human, almost rebellious.
The new logo pops against the Cybercab’s smooth, metallic body, turning the autonomous pod into a rolling piece of public art rather than just another futuristic taxi.
Designers know that fonts are silent brand ambassadors. They shape perception before a single ride is taken. Tesla’s classic sans-serif aesthetic screams precision engineering and Silicon Valley cool.
The new Robotaxi script leans into accessibility and fun, suggesting the vehicle is approachable, not intimidating. For a product meant to ferry strangers through city streets 24/7, that matters. It signals that the robotaxi isn’t reserved for tech elites; it’s for everyone.
Tesla Cybercab spotted next to Model Y shows size comparison
The timing is no accident. With regulatory approvals for unsupervised autonomy advancing and Tesla preparing to scale Cybercab production, the company is shifting from prototype showcase to fleet deployment.
A fresh logo helps differentiate the vehicles visually in dense urban environments—crucial for rider recognition and brand recall. It also aligns with Elon Musk’s long-standing ethos: make the future feel exciting, not sterile.
Small changes like this often foreshadow a larger strategy. Tesla has always obsessed over details—door handles, screen interfaces, even the curvature of a steering wheel.
Updating the Robotaxi font reflects the same meticulous care now applied to consumer-facing autonomy. It’s not just paint on metal; it’s a statement that the ride of the future should feel personal, memorable, and undeniably cool.
In an industry racing toward self-driving fleets, Tesla’s willingness to evolve even the smallest visual cues shows confidence. A font won’t launch the robotaxi network, but it might just help millions climb aboard with a smile.
News
Tesla makes latest announcement on Model S and Model X
The announcement follows Tesla CEO Elon Musk’s statement on the Q4 2025 earnings call in late January. Musk described the decision as an “honorable discharge” for the two vehicles, noting that production would wind down in Q2 2026.
Tesla has officially begun winding down production of its flagship Model S and Model X in the United States, notifying owners via email that the long-running models will soon reach the end of the line.
The email, sent to U.S. customers on March 27, opens with gratitude. “Model S and Model X marked the beginning of the world’s transition to electric transportation,” it reads. “These vehicles also made it possible for Tesla to develop the technology that would move our world toward autonomy.”
It then delivers the news directly: “As we make way for this autonomous future, Model S and Model X production will be ending. If you’d like to bring home a new Model S or Model X, order yours soon from our limited inventory.”
Tesla just sent out a new email thanking Model S/X owners.
“These vehicles made it possible for Tesla to develop the technology that would move our world toward autonomy. As we make way for this autonomous future, Model S and Model X production will be ending. If you’d like to… pic.twitter.com/IeUhZ3iDnX
— Sawyer Merritt (@SawyerMerritt) March 27, 2026
The message closes with a simple thank-you: “Thank you for being part of our journey.”
The announcement follows Tesla CEO Elon Musk’s statement on the Q4 2025 earnings call in late January. Musk described the decision as an “honorable discharge” for the two vehicles, noting that production would wind down in Q2 2026.
The move frees factory floor space at Fremont, California, for next-generation manufacturing, including Optimus humanoid robots and the upcoming Robotaxi platform.
Introduced in 2012 and 2015, respectively, the Model S and Model X were Tesla’s original halo cars. They proved EVs could outperform gasoline luxury vehicles in acceleration, range, and tech features while pioneering over-the-air updates and early autonomy hardware.
Although they never matched the volume of the Model 3 and Model Y, their engineering breakthroughs laid the foundation for the company’s current lineup and full self-driving development.
Early adopters highlighted how the cars convinced them to invest in Tesla stock and the EV movement. Some U.S. owners who had not yet received the note voiced mild frustration, and international customers confirmed the outreach remains U.S.-only for now.
Tesla has not detailed an exact final production date beyond the Q2 2026 target or confirmed immediate replacements. Speculation continues about a possible Cybertruck-derived SUV, but the company’s public focus has shifted squarely to autonomy and robotics.
For buyers still interested in the S or X, the window is closing. Inventory is described as limited, and Tesla’s Korean division has already set a March 31 cutoff for new orders in that market. The email serves as both a farewell and final sales push, an elegant close to a chapter that helped define modern electric driving.
Tesla FSD mocks BMW human driver: Saves pedestrian from near miss
Tesla Robotaxi gets a small but significant change
Tesla makes latest announcement on Model S and Model X
Elon Musk says Tesla is developing a new vehicle: ‘Way cooler than a minivan’
Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry
