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Tesla streamlined Model 3 battery pack production time by 96%, says Elon Musk

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Tesla CEO Elon Musk stated during Wednesday’s Q1 2018 earnings call that the company has managed to reduce the time it takes to produce a Model 3 battery pack by 94%, from 7 hours to under 17 minutes. According to Musk, addressing the over-generalization of the Model 3’s design, as well as the excessive automation in Gigafactory, proved beneficial to the improvement in the manufacturing rate of the car’s battery packs.  

“This still remains to be fixed, but in any case, overgeneralizing the design. For example, the current battery pack has a port for front drive units, which we then put a steel blanking plate on. So essentially, we punched a hole in it and put a blanking plate at the hole. And (we had to) do that for all rear drive unit cars, which is kinda crazy.

“It would have added cost, it would have added a manufacturing step, it would have added a failure mode; and four ports was unnecessary… That’s changed. So, the result was we had a rapid improvement in battery pack production, from taking 7 hrs to make a pack 3 weeks ago to under 17 minutes now. We’re able to also achieve a sustained rate of 3,000 vehicles a week, so we’re actually slightly ahead in battery module and pack production than expected.”

With the optimizations to the line in place, Musk revealed that Tesla is now producing 3,000 battery packs per week at the Nevada Gigafactory, with peak hours of production hitting a rate of 5,000 per week. 

“In the last 24 hours at the Gigafactory, we managed to keep a sustained rate of over 3,000 packs per week. We actually reached a peak hour, extrapolated outward would be a rate of over 5,000 cars per week… Every hour is as good as its peak. If you can achieve it even once in an hour, then with continued refinement of the system, and improved operational time of the machinery, you can achieve that sustained rate with more refinement.” 

Musk reiterated his previous statement about the company automating too much of its production line. According to Musk, Tesla “went too far and automated some pretty silly things,” including an incredibly complex “fluff machine” that ended up making production complicated. 

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“One of the things we’ve found is that there are some things that are very well suited to manual operations, and there are some things are very well suited to automated operations. The two should not be confused. We did go too far in the automation front, and automated some pretty silly things.

“One example would be, we have these fiberglass mats on top of the battery pack. They’re basically fluff. We tried to automate the placement and bonding of fluff to the top of the battery pack, which was ridiculous. ‘Flufferbot,’ which was really an incredibly difficult machine to make work. Machines are not good at picking up pieces of fluff. Hands are way better at doing that.

“So we had this super-complicated machine, using a vision system to try and put a piece of fluff on a battery pack. The line kept breaking down because Flufferbot would frequently fail to pick up the fluff, or put it in a random location. So, that was one of the silliest things we’ve found.”

The revelations about the improvements in the pace of Model 3 battery pack production are in line with Elon Musk’s recent statements about relying too much on automation. Musk mentioned this in an interview with Gayle King of CBS This Morning, and later in a tweet, where he coyly stated that humans are “underrated.”

Nevertheless, Tesla pointed to strategic automation as key in its Q1 Update Letter. The company, for one, credits the quality improvements in the Model 3 line to the automation that is involved in manufacturing the vehicles. Tesla expects the Model 3 line to be optimized once more after a planned 10-day shutdown in production during the second quarter. With a hiring ramp underway, Tesla is aiming to adjust overtime hours and staffing levels to meet its production goals even further.

Tesla’s first-quarter earnings for 2018 saw the electric car maker posting $3.4 billion in revenue and beating earnings estimates with a loss of $568 million. Losses per share was listed at -$3.35 per share, lower than Wall Street estimates of -$3.58 per share.

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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 and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

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Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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Tesla uber bull Ron Baron says ‘the time to buy the stock is now’

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Credit: Tesla

In a new interview on Wednesday, Tesla uber bull Ron Baron said that anyone looking to buy the company’s stock should do so as soon as they can.

Baron, founder and CEO of Baron Capital and one of Tesla’s most persistent institutional bulls, used a CNBC Squawk Box appearance on Wednesday to deliver a familiar message with fresh urgency: In his opinion, Tesla stock is a buy:

“The time to buy the stock is now. FSD is catching on, and it’s going to be bigger and bigger. 55% of new buyers are buying it (Teslas) with FSD. It’s going to be everywhere. It’s safer.”

The Baron Capital frontman’s case is built around Full Self-Driving. Tesla reported 1.48 million active FSD subscriptions in the second quarter, up 56 percent year over year, and company officials have said roughly 55 percent of new North American deliveries left with a subscription enabled.

Baron framed that attach rate as proof the product is moving from enthusiast extra to default expectation, and as a reason software, not just vehicle volume, should drive the next phase of value.

His conviction on Tesla shares is not theoretical, as Baron Capital made its first Tesla investment in 2014, after years of meetings that began around the 2010 IPO roadshow. The firm later built a large SpaceX position starting in 2017.

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Baron said those Musk-led bets have generated about $30 billion of the $71 billion in profits Baron Capital has produced for clients. He put the firm’s current exposure at roughly $25 billion in SpaceX and $5 billion in Tesla. Personally, he described SpaceX as his largest holding, at about $5 billion, with about $1.5 billion in Tesla and additional Tesla exposure through the firm’s funds.

That concentration is also a statement of loyalty. Asked about talk of a SpaceX-Tesla combination, Baron said he had already walked Elon Musk through arguments for and against a deal, then declined to repeat them on air. His public position was simpler: “Whatever you decide is better is what I’m going to support,” he said to Musk.

Baron also said that he picked up the farewell edition of the Model S after Tesla decided to sunset the vehicle earlier this year, calling it his favorite car he’s ever driven.

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Elon Musk gives his most telling Tesla-SpaceX merger conversation yet

Elon Musk hinted a Tesla-SpaceX merger could be coming, and Wall Street is taking notice.

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Elon Musk gave his clearest signal yet that Tesla and SpaceX could eventually combine, telling the All-In Summit in Los Angeles that the two companies’ deepening collaboration makes the question worth asking. Sawyer Merritt first surfaced the highlight on X Tuesday.

Asked directly why Tesla and SpaceX remain separate given how closely they already work together, Musk told hosts at the summit: “Great question there. With all this collaboration, on so many levels, who can imagine what action one might take when there’s so much close collaboration in so many areas.” SpaceX President Gwynne Shotwell, who joined Musk on stage, added that SpaceX personnel have already moved into xAI to fill leadership and engineering gaps, saying the businesses are integrating “faster than I thought,” though “not fully integrated yet,”

The comments landed on top of merger speculation that has been building on Wall Street for months. JPMorgan has called a tie-up “strategically coherent on paper,” pointing to overlapping ambitions in AI, robotics, energy, transportation and space. Jefferies went further, estimating Musk could retain roughly 55.3 percent voting control in a deal structured without a premium, a scenario that would still leave room for Tesla shareholders to come out ahead. On Kalshi, traders now put the odds of a merger before 2028 at 66 percent.

Tesla’s stake in SpaceX, still under one percent, traces back to its earlier investment in xAI, which converted to SpaceX equity after SpaceX absorbed the AI company. The two are also jointly building Terafab, a chip facility in Austin meant to serve both Tesla’s AI computing needs and SpaceX’s satellite ambitions. Wedbush analyst Dan Ives has stood by a 2027 merger timeline for months, and Cathie Wood’s ARK Invest recently floated a similar case, an idea Musk pushed back on directly at the time.

Another Tesla SpaceX merger prediction by ARK Invest has Elon Musk talking

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The timing adds another layer. Tesla has scheduled an October 1 unveiling for its next generation Roadster at a venue near SpaceX’s McGregor, Texas test site, using the phrase “Go for launch” in its promotional material. Both stocks dipped roughly 2 percent Monday before recovering slightly in premarket trading Tuesday, with SpaceX shares up about 0.4 percent and Tesla essentially flat.

Musk stopped short of confirming anything is in motion. But unlike his past denials of a corporate restructuring, this response didn’t rule one out, and it came with Shotwell sitting next to him describing an integration that’s already underway.

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