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Tesla Model 3 single-piece casting will come, but not anytime soon, Elon Musk says
Tesla will “likely” switch the Model 3 sedan to a single-piece casting design in the future, CEO Elon Musk said in an interview with Sandy Munro. However, the design will not be on its way anytime soon, as Musk said the Berlin and Texas Gigafactories need to have production efforts well underway to sustain demand fulfillment.
The Model 3’s current design is not a single piece casting and is comprised of 70 different metal parts welded together to create the vehicle’s underbody. Tesla improved upon this design in its Model Y crossover by using a massive, single-piece casting to eliminate 69 total parts. The single-piece design is effective for manufacturing purposes and increases structural rigidity in the event of an accident.
As the Model Y and Model 3 dominate Tesla’s current sales and delivery figures, Munro mentioned to Musk that he was disappointed that his new Model 3 teardown did not reveal a single piece casting similar to the Model Y design. However, Musk indicated Tesla’s mass-market sedan would eventually use the single-piece casting, it would just take its next two production facilities to be in operation for it to happen.
Musk told Munro:
“At some point, we probably will switch to a single-piece casting, but I think we need to get the Texas factory and the Berlin factory going. We do have an issue. It is hard to change the wheels on the bus when it is going 80 MPH down the highway. So, Model 3 is…well, was most of our volume. Model Y will exceed Model 3, but we just need an opportunity to redo the factory without blowing the cash flow of the company.”
In its Q1 2020 Update Letter, Tesla showed the two designs. The Model Y casting (right) was two pieces at this point in time. Thanks to the introduction of Tesla’s Giga Press from IDRA, the automaker has eliminated the two-piece design in favor of a massive one-piece casting. The elimination of so many parts was a huge advantage for Munro, who detailed the casting advantages in several teardown episodes last year.
Tesla Model Y owner Tony Pham then showed the one-piece casting design on his vehicle while having a third-party accessory installed into his all-electric crossover. Pham’s Model Y was delivered in late 2020, proving that Tesla has been utilizing the one-piece design for several months.
Model Y single piece rear casting!
VIN 97k, delivered 12/23/2020. Thanks @TeslaFrunk for the rear kick sensor installation pic.twitter.com/jkIGwX265v— Tony Pham – “Quick Bandit” license plate mount (@TonyTesla4Life) January 10, 2021
Tesla’s single-piece design is widely thought by automotive engineers, including Munro, to be the most advantageous way to build a car. In Munro’s opinion, other automakers have ignored a single-piece design’s advantages due to their stubbornness to keep things the same. “Thousands of engineers, big-time executives, walk by [the idea]. They don’t do it,” Munro said.
One of Tesla’s manufacturing process’s main advantages is that it continues to refine its techniques and never admits that its current processes are the best way to handle things. Tesla is always looking to improve the situation of its manufacturing and production lines, always seeking different techniques and new ways to build its vehicles. The issue now is that Tesla’s vehicles are becoming so popular that its limited production lines cannot be halted to update some production techniques, especially to mass-market vehicles that have been produced for several years. Musk’s analogy of the bus going 80 MPH down the highway is extremely accurate, especially as Tesla is coming off of its largest production and delivery year in company history. Halting Model 3 production lines for an update to the vehicle’s casting design would be detrimental at the current time.
While it is likely that Model 3 single-piece castings could happen down the road, it is not something to expect soon. With Musk indicating that Giga Berlin and Giga Texas need to be in operation for this to occur, these facilities will likely need to have Model 3 production numbers high enough to offset the closure of lines at Giga Shanghai and Fremont. With Berlin focusing on Model Y production initially, it is likely that Model 3 lines will not be ramped for at least a year, so the single-piece Model 3 casting may not be seen until at least 2023.
Elon Musk’s full interview with Sandy Munro is available below.
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Tesla announces major milestone at Gigafactory Shanghai
First deliveries started in December 2019, with the first units being given to employees. By the end of 2020, the plant was building cars at a run rate of around 150,000 vehicles annually.
Tesla has announced a major milestone at its Chinese manufacturing facility, Gigafactory Shanghai, confirming on Monday that it had built its four millionth vehicle.
Tesla Gigafactory Shanghai first started building cars back in October 2019 with Model 3 assembly, just ten months after the company broke ground on the plant’s 86-hectare piece of land.
First deliveries started in December 2019, with the first units being given to employees. By the end of 2020, the plant was building cars at a run rate of around 150,000 vehicles annually. Production continued to ramp up, and by September 2023, less than three years after it started building Tesla’s EVs, it had built its two millionth vehicle.
Fast forward to December 2025, and Tesla has confirmed that four million cars have rolled off of production lines at the plant, a major milestone in the six short years it has been active:
Produced our 4 millionth vehicle at Gigafactory Shanghai🎉
Thanks to all our owners and supporters❤️ pic.twitter.com/DayVXUr220— Tesla Asia (@Tesla_Asia) December 8, 2025
The capacity at Giga Shanghai is exceeding 950,000 vehicles per year, and this year, the company has delivered 675,000 cars through the first three quarters. It is also the only plant to manufacture the Model Y L, a longer wheel-based configuration of the all-electric crossover that is exclusive to the Chinese market.
Gigafactory Shanghai’s four million cars have not all stayed within the domestic market, either. For a considerable period, the factory was exporting a significant portion of its monthly production to Europe, helping Gigafactory Berlin supplement some Model Y volume and all of its Model 3 deliveries. This is due to the Berlin plant’s exclusive production plans for the Model 3.
The site is one of the most crucial in the company’s global plans, and Gigafactory Shanghai’s incredible pace, which has led to four million production units in just about six years. It’s fair to say that it won’t be long until we’re seeing Tesla celebrate the plant’s five millionth vehicle produced, which should happen sometime late next year or in early 2027, based on its current manufacturing pace.
The company also builds the Megapack on the property in an adjacent Megafactory.
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Tesla gamifies Supercharging with new ‘Charging Passport’
It will also include things like badges for special charging spots, among other metrics that will show all of the different places people have traveled to plug in for range.
Tesla is gamifying its Supercharging experience by offering a new “Charging Passport,” hoping to add a new layer to the ownership experience.
While it is not part of the Holiday Update, it is rolling out around the same time and offers a handful of cool new features.
Tesla’s Charging Passport will be available within the smartphone app and will give a yearly summary of your charging experience, helping encapsulate your travel for that year.
It will also include things like badges for special charging spots, among other metrics that will show all of the different places people have traveled to plug in for range.
Tesla has just introduced “Charging Passport,” a new yearly summary of your charging.
• Charging badges: Iconic Charging badge (for visiting places like the Tesla Diner, Oasis Supercharger, etc), Explorer badge, green saver badge, etc.
• Total unique Superchargers visited
•… pic.twitter.com/c1DHTWXpj7— Sawyer Merritt (@SawyerMerritt) December 8, 2025
Tesla will include the following metrics within the new Charging Passport option within the Tesla app:
- Charging badges: Iconic charging badges for visiting places like the Tesla Diner, Oasis Supercharger, etc., Explorer Badge, and more
- Total Unique Superchargers Visited
- Total Charging Sessions
- Total Miles Added during Charging Sessions
- Top Charging Day
- Longest Trip
- Favorite Charging Locations
This will give people a unique way to see their travels throughout the year, and although it is not necessarily something that is needed or adds any genuine value, it is something that many owners will like to look back on. After all, things like Spotify Wrapped and Apple Music Replay have been a great way for people to see what music they listened to throughout the year.
This is essentially Tesla’s version of that.
With a handful of unique Superchargers already active, Tesla is also building some new ones, like a UFO-inspired location in New Mexico, near Roswell.
Tesla is building a new UFO-inspired Supercharger in the heart of Alien country
News
Tesla launches its coolest gift idea ever just a few weeks after it was announced
“Gift one month of Full Self-Driving (Supervised), which allows the vehicle to drive itself almost anywhere with minimal intervention.”
Tesla has launched its coolest gift idea ever, just a few weeks after it was announced.
Tesla is now giving owners the opportunity to gift Full Self-Driving for one month to friends or family through a new gifting program that was suggested to the company last month.
The program will enable people to send a fellow Tesla owner one month of the company’s semi-autonomous driving software, helping them to experience the Full Self-Driving suite and potentially help Tesla gain them as a subscriber of the program, or even an outright purchase.
Tesla is going to allow owners to purchase an FSD Subscription for another owner for different month options
You’ll be able to gift FSD to someone! https://t.co/V29dhf5URj
— TESLARATI (@Teslarati) November 3, 2025
Tesla has officially launched the program on its Shop. Sending one month of Full Self-Driving costs $112:
“Gift one month of Full Self-Driving (Supervised), which allows the vehicle to drive itself almost anywhere with minimal intervention. All sales are final. Can only be purchased and redeemed in the U.S. This gift card is valued at $112.00 and is intended to cover the price of one month of FSD (Supervised), including up to 13% sales tax. It is not guaranteed to cover the full monthly price if pricing or tax rates change. This gift card can be stored in Tesla Wallet and redeemed toward FSD (Supervised) or any other Tesla product or service that accepts gift card payments.”
Tesla has done a great job of expanding Full Self-Driving access over the past few years, especially by offering things like the Subscription program, free trials through referrals, and now this gift card program.
Gifting Full Self-Driving is another iteration of Tesla’s “butts in seats” strategy, which is its belief that it can flip consumers to its vehicles and products by simply letting people experience them.
There is also a reason behind pushing Full Self-Driving so hard, and it has to do with CEO Elon Musk’s compensation package. One tranche requires Musk to achieve a certain number of active paid Full Self-Driving subscriptions.
More people who try the suite are likely to pay for it over the long term.
Tesla announces major milestone at Gigafactory Shanghai
Tesla gamifies Supercharging with new ‘Charging Passport’
