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Tesla Model 3 named as vehicle with ‘lowest probability of injury’ by the NHTSA

[Credit: NHTSA]

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The National Highway Traffic Safety Administration (NHTSA) has dubbed the Long Range RWD Tesla Model 3 as the vehicle with the lowest probability of injury among all cars that the agency has tested so far. The Model 3’s low likelihood of injury rating was given after the vehicle went through the NHTSA’s New Car Assessment Program, which involves a series of crash tests determining the likelihood of serious passenger injury for front, side, and rollover crashes. 

The Model 3’s stellar rating from the NHTSA could be seen as yet another testament to the quality of Tesla’s all-electric cars. Immediately following the Model 3’s scores, after all, are the Model S and Model X, which are currently the vehicles considered by the NHTSA with the second and third lowest probabilities of injury. In a blog post announcing the electric sedan’s safety ratings, Tesla noted that it expects the Dual Motor AWD Model 3 to perform just as well in the NHTSA’s tests as its Long Range RWD sibling.

Part of the reason why the Model 3 is so safe is due to the vehicle’s all-electric design. Tesla opted to place the Model 3’s battery pack, the heaviest component of the vehicle, right at the car’s center of gravity. This gives the Model 3 performance and handling that is almost similar to that of mid-engine vehicles, while allowing the electric sedan to have a near 50/50 weight distribution. Other subtle design tweaks, such as the rear motor being placed slightly in front of the axle, further improve the Model 3’s weight distribution, as well as its overall agility and handling.

In true Tesla tradition, the Model 3’s all-electric architecture comprises of a sturdy, rigid passenger compartment, a fortified battery pack, and a low center of gravity. Just like its larger siblings, the Model S and X, the absence of an internal combustion engine in front and a fuel tank at the rear give the Model 3 extra large crumple zones, which are optimized to absorb energy and crush more efficiently in the event of an accident.

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In the event of a frontal crash, the crumple zone at the front of the vehicle controls the deceleration of occupants, while the Model 3’s advanced restraint systems keep occupants safe in place. Passenger airbags are even specially designed to protect an occupant’s head in the event of an angled or offset crash, while active vents enable the vehicle to adjust the internal pressure of the frontal airbags when deploying. These systems optimize protection based on the specifics of an accident.

The Model 3’s energy-absorbing lateral and diagonal beam structures help occupants safe during pole impact crashes. These structures include a high-strength aluminum bumper beam, a sway bar placed close and forward in front of the car, cross members are the front of the steel subframe that are connected to the main crash fails, as well as diagonal beams in the subframe that distribute energy back to the crash rails when they are not directly impacted. An ultra-high-strength martensitic steel beam is further fitted on the front of the suspension to absorb crash energy from severe impacts.

The Tesla Model 3 gets crash tested by the National Highway Traffic Safety Administration. [Credit: NHTSA]

Tesla also designed the Model 3 with a patented pillar structure and side sills to absorb as much energy as possible in a short distance. Coupled with the vehicle’s rigid body construction and fortified battery architecture, these design elements enable the Model 3 to reduce and prevent compartment intrusion in the event of an accident, while allowing its side airbags to have more space to inflate and cushion occupants.

Just like the Model S and Model X, the Model 3’s low center of gravity plays a key role in keeping the vehicle safe from rollover crashes. That said, even if a rollover does occur, Tesla notes that internal tests have shown that the Model 3 is capable of withstanding roof-crush loads equivalent to more than four times the electric sedan’s weight, far more than the NHTSA’s standards that require cars to withstand three times their own weight.

The Model 3 was recently given a flawless 5-Star Safety Rating in all categories and subcategories by the NHTSA. In a follow-up tweet to the NHTSA’s Model 3 results, Elon Musk noted on Twitter that the electric sedan has a shot at being the “safest car ever tested” by the agency. With the Model 3 being dubbed as the vehicle with the lowest probability of injury by the NHTSA, it appears that Musk’s statement has proven to be accurate.

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It’s not just the NHTSA that has given the Model 3 its approval, either. Earlier this year, the Insurance Institute for Highway Safety (IIHS), a nonprofit funded by auto insurers aimed at reducing accidents on the road, gave the Model 3 a “Superior” front crash avoidance rating. During the course of its testing, the Model 3 performed well in the crash avoidance and mitigation category, thanks to the vehicle’s Forward Collision Warning, its low-speed autobrake, and its high-speed autobrake systems. The Model 3 was also given a “Recommended” rating by Consumer Reports, after an over-the-air software update reduced the vehicle’s braking distance.

Tesla’s electric cars are known for their performance and their safety. The Model X, for one, also received 5-Star Safety Ratings in all categories and subcategories during the NHTSA’s tests. The Model S, on the other hand, performed so well during the NHTSA’s safety evaluation that the agency’s crash-testing gear broke while it was testing the electric sedan.

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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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

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Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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