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Tesla Model 3 single-piece casting will come, but not anytime soon, Elon Musk says

Elon Musk gives a rare look into the Model 3 production line. [Credit: CBS This Morning/YouTube]

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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.”

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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.

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.

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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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Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Investor's Corner

Tesla (TSLA) Q3 2025 earnings: Wall Street’s reactions

Tesla’s third-quarter 2025 results delivered the highest quarterly revenue in company history, and Wall Street analysts are taking notice. 

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Credit: Tesla

Tesla’s third-quarter 2025 results delivered record quarterly revenues, and Wall Street is taking notice. 

The automaker reported $28.1 billion in revenue, topping estimates of $26.4 billion, while non-GAAP EPS landed at $0.50 versus $0.54 expected. Despite the slight earnings miss, Tesla’s free cash flow surged to nearly $4.0 billion and total cash on hand jumped to $41.6 billion, a new high.

The following are some of Wall Street’s reactions to Tesla’s third-quarter results.

Mizuho

Mizuho analyst Vijay Rakesh maintained an “Outperform” rating on Tesla and raised the firm’s price target to $485 from $460 per share, pointing to Tesla’s next-generation autonomy roadmap. “We see 2026E better with stronger FSD traction and deliveries. TSLA is focusing on AI5/HW5 with ~40x gains gen/gen, while ramping Robotaxis and FSD into 2026E–27E.”

Rakesh also highlighted that Mizuho sees Tesla as “well-positioned” to lead “physical AI with Cybercab/FSD traction, humanoid longer term, offset by near-term demand headwinds.”

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Wedbush

Wedbush analyst Dan Ives reiterated his “Outperform” rating and $600 price target on Tesla. As per the analyst, “Tesla reported its FY3Q25 results featuring beats on the top-line while missing bottom-line expectations as the company benefitted from a pull-forward in its delivery segment with greater strength across EMEA and APAC while making gradual progress with its autonomous and energy businesses.” 

He also pointed to Musk’s upcoming compensation vote as a key inflection point: “We believe it will be approved by a wide margin despite some opposition,” Ives noted. “That will be incremental to keeping Musk as a war-time CEO as the company enters a critical AI expansion phase.”

Baird

Baird analyst Ben Kallo reiterated his “Outperform” rating and $548 per share price target for Tesla following the company’s Q3 2025 earnings results. He praised Tesla’s energy segment for delivering record results. 

“Energy demand is particularly high given grid constraints in several regions and a rapid build-out of infrastructure. We expect this piece of the business to capture more attention in the remainder of 2025 and moving into 2026 with the tipping points for longer-term initiatives (Optimus, robotaxi, etc.) more opaque,” Kallo noted.

Deepwater

Meanwhile, Deepwater’s Gene Munster struck a more measured tone. “The September numbers and earnings call were largely uneventful,” Munster said, adding that Tesla’s decision to move cautiously with robotaxis in Austin is the right one. 

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“Shares of TSLA traded down following Elon’s comment that he remains paranoid about the safety of Robotaxi given any accidents would represent a significant step back in terms of the public’s confidence in the fleet,” he wrote. Munster, however, emphasized that Tesla’s cash position is a major strength: “They have enough cash to will Elon’s vision into reality. It may take a lot longer than many expect, but they’ve got the cash to get there.”

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Investor's Corner

Tesla’s massive Q3 update reaffirms it’s not just a car company anymore

From record global deliveries to new AI breakthroughs, Megablock energy tech & next-gen Superchargers, Tesla showed why it’s still miles ahead.

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Credit: Tesla Asia/X

Tesla’s third-quarter update showcased a flurry of milestones across its vehicles, AI, and energy divisions. The company achieved record deliveries and energy storage deployments while launching new products in North America, EMEA, and Asia-Pacific. 

Tesla also emphasized its focus on scaling AI-powered autonomy and virtual power plant technology as part of its push towards Master Plan Part IV.

Global product rollouts and record regional performance

Tesla’s Q3 highlights revealed strong traction across multiple continents. In North America, the automaker launched the new Model 3 and Model Y Standard variants, each offering over 300 miles of range and starting below $40,000. The Model Y Performance also debuted, highlighting Tesla’s focus on sheer performance and driving dynamics.

In Europe and the Middle East, Model Y topped sales charts in Norway, Switzerland, Iceland, and Finland while reaching number one in the Netherlands and Denmark in September. Giga Berlin celebrated production of its 100,000th refreshed Model Y, including the first European-built Performance units. Tesla confirmed it’s working toward regulatory approval for its FSD Supervised software in Europe.

Across Asia-Pacific, Tesla introduced the Model YL in China, an extended wheelbase, six-seat version of its best-selling crossover SUV, and achieved record deliveries in South Korea, Taiwan, Japan, and Singapore. The company also began Model Y deliveries in India, launched FSD Supervised in Australia and New Zealand, and confirmed South Korea is now its third-largest global market.

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AI, charging, and energy divisions

Tesla’s AI division rolled out version 14 of FSD Supervised, integrating key elements of its Robotaxi model and improving responses to complex driving scenarios. The company expanded its Austin Robotaxi fleet and launched a Bay Area ride-hailing pilot while announcing a U.S. semiconductor manufacturing deal with Samsung to boost AI compute capacity.

Tesla also introduced Grok, an AI vehicle companion, alongside new vehicle software like Low Power Mode and Light Sync. The company also introduced minor but notable convenience improvements, such as the ability to order food directly from the vehicle at the Tesla Diner in LA.

Meanwhile, Tesla’s energy business achieved record storage deployments and revealed “Megablock,” a next-generation industrial product built around Megapack 3s, slated for production in Houston by 2026. The Superharger Network grew 18% year-over-year as well, adding over 3,500 Supercharger stalls and debuting V4 cabinets capable of 500 kW passenger charging and up to 1,200 kW for Tesla Semi trucks.

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Tesla reveals its plans for Hardware 3 owners who are eager for updates

“We have not completely given up on HW3. These customers are very important. They are early adopters. We will definitely take care of you guys.”

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Tesla-Chips-HW3-1
Image used with permission for Teslarati. (Credit: Tom Cross)

Tesla has finally revealed its plans for Hardware 3 owners who are eager to have access to the latest versions of the company’s Full Self-Driving suite.

Tesla’s Hardware 3 vehicles feature an older chip that does not immediately give access to new versions of the FSD suite. Cars like the new Model Y have Hardware 4, often referred to as AI4, while Tesla is already working to develop AI5 chips with suppliers TSMC and Samsung.

However, during the Q3 Earnings Call on Wednesday, Tesla finally gave some information to those Hardware 3 owners who have been anxiously waiting for updates, and hopefully, this will give them some peace of mind.

Tesla (TSLA) Q3 2025 earnings results

The comments came from Chief Financial Officer Vaibhav Taneja, who said that he is also impacted by the HW3 delays because his daily commuter is a HW3 vehicle.

He said:

“We have not completely given up on HW3. These customers are very important. They are early adopters. We will definitely take care of you guys.”

Additionally, Tesla’s Head of AI and Autopilot, Ashok Elluswamy, added that the company plans to offer a v14 Lite version of the Full Self-Driving (Supervised) suite in Q2 of next year.

The company has tried to give HW3 owners more opportunities to trade in their cars for new vehicles, giving them the opportunity to have access to the latest FSD software versions, which are prioritized for HW4 vehicles.

However, it is easier said than done to simply trade in your car and commit to a long-term financial commitment. For this reason, many HW3 owners have grown incredibly frustrated with how Tesla has handled the situation, especially considering they have been told they would be taken care of for several quarters now.

It appears that these owners will be waiting a tad longer for any sort of true progress, unless they have an interest in using the FSD transfer to get a new vehicle without paying for the suite once again.

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