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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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U.S. Secret Service in talks for armored cars with this automaker

The Secret Service says it’s still too early to know the future of a potential deal for these “highly-advanced vehicles.”

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Credit: Jeffrey Sauger (via GM)

The U.S. Secret Service has entered early discussions with one automaker about the potential supply of armored SUVs, as announced by the agency this week.

In a post on X on Friday, the Secret Service account posted that Director Sean Curran recently met with executives from General Motors (GM) to discuss a potential next-generation of armored SUVs. The post also included photos of a Cadillac Escalade SUV, along with a few of executives talking about and showing off hardware from the next-gen platform.

“Countering evolving threats require us to constantly explore new innovations and improvements to our armored fleet of protective vehicles,” the account wrote in the post. “Director Sean Curran met with GM executives to discuss advancements that could benefit the next generation of armored SUVs.”

Credit: U.S. Secret Service | X

Credit: U.S. Secret Service | X

Currently, U.S. President Donald Trump typically utilizes an armored Chevy Suburban to get around, and the Secret Service said that it isn’t yet clear when such a next-gen “presidential limousine” could be added to the fleet. The news also comes after GM CEO Mary Barra met with Trump last week, reportedly also to discuss armored SUVs.

READ MORE ON U.S. GOVERNMENT: This former Tesla engineer now heads a federal tech department

“We are too far out to speak to any specific costs or dates,” one Secret Service spokesperson told Reuters. “Our engineering, protective operations and technical security teams work for years to develop the state-of-the-art framework that is used to produce these highly advanced vehicles.”

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Many in the thread also said that the Tesla Cybertruck could be a good option for the Secret Service, coming weeks after the U.S. State Department apparently canceled a potential $400 million Cybertruck order after it was widely reported on. State Department officials have since said that the figure listed in documents for the deal, which was first initiated under the Biden administration, were simply an estimate, and the Cybertruck has been removed from the broadly reported procurement list.

CEO Elon Musk also responded to the reports on X, suggesting that they were either misunderstood or false, noting that he was “pretty sure Tesla isn’t getting $400 million.”

“No one mentioned it to me, at least,” Musk added in the post.

The Cybertruck features a stainless steel exterior that has been touted by Tesla as being able to withstand bullets and other potential attacks. Tesla Cybertrucks have also been rolling out to some U.S. Police Departments in recent months, many featuring armored tune-ups from Unplugged Performance’s Up.Fit government and military fleet division.

Irvine PD unveils Tesla Cybertruck DARE program fleet unit

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Tesla Powerwalls to help expand Virtual Power Plant in Colorado

Colorado’s Virtual Power Plant program is about to get even bigger, with the help of Tesla’s Powerwalls.

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Tesla’s Powerwalls are set to help expand a Virtual Power Plant (VPP) program in Colorado, as an announcement this week notes that the company will be partnering with two local energy providers.

In a press release on Thursday, utility provider Xcel Energy and resource management company Itron announced a partnership with Tesla to help expand the existing VPP in Colorado, dubbed the Renewable Battery Connect program. Itron will integrate its IntelliFLEX platform with Tesla’s Powerwall management system, and the partners plan to increase the number of batteries that can be used during times of peak demand, as managed by Xcel.

The IntelliFLEX Aggregator Distributed Energy Resource Management System (DERMS) is designed to let energy providers localize the management of distributed batteries, utilizing a combination of residential battery storage, solar energy, electric vehicle (EV) chargers and other management systems to help balance grid energy more efficiently.

“Our Renewable Battery Connect program creates a new VPP in Colorado and we’re proud to work with Itron and Tesla, who have proven to be trusted industry partners and align with our goals to strengthen the energy grid while maintaining reliability and advancing renewable energy,” said Emmett Romine, Xcel’s VP of Customer Energy and Transportation Solutions. “This collaboration will deliver renewable, solar energy when our customers need it most.”

READ MORE ON TESLA POWERWALLS: Tesla partners up to expand Virtual Power Plant program in Texas

Itron also says the IntelliFLEX system currently helps facilitate around three million distributed energy resource devices for 30 different utilities across the U.S. The company also says the tool will give Xcel more power to manage customers’ residential batteries to help stabilize local grids.

“Integrating our IntelliFLEX solution with Tesla Powerwall demonstrates a shared vision with a leading technology partner who is at the forefront of creating electrification solutions,” said Don Reeves, SVP of Outcomes at Itron. “Through this collaboration, we are excited to bring new capabilities to Xcel Energy as they embark on its energy transition journey.”

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Tesla’s Powerwall home batteries have been utilized in markets around the world, effectively letting owners store and sell stored energy back to the electrical grid in times of peak demand, outages, and other peak use cases. This kind of distributed battery system is being piloted or run in a number of U.S. states, including California, Texas, and Massachusetts, and in a few other countries and territories.

The company currently builds Powerwalls at its Gigafactory in Nevada, and the facility in November celebrated building over 1,000 of the home batteries in a single day as it continues to ramp production. In October, Tesla also said that it had over 100,000 Powerwalls participating in its VPP programs worldwide.

Tesla shows off solar, Powerwall-backed display at Giga Berlin

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Tesla quietly added this extra Sentry Mode feature to deter vandals

Tesla’s Sentry Mode gets another feature, set to add an extra layer of security against vandalism.

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Credit: Tesla

Amidst increased vandalism events against Tesla’s vehicles in recent weeks, the company’s Sentry Mode has increasingly been in the spotlight as a deterrent for criminal activity. As part of an update to its website this week, Tesla has also revealed a subtle addition to the recording system that should help deter vandals caught in the act.

Tesla’s Sentry Mode on Cybertrucks will soon play music at the maximum volume when the vehicle’s cameras detect activity, as detailed on the company’s redesigned Cybertruck web page this week and initially spotted by Not a Tesla App. The detail was quietly added to the Cybertruck web page, as part of the larger Sentry Mode suite of features that lets owners check out the external cameras on their electric vehicles (EVs) even when away.

“Enable Sentry Mode to monitor your unattended vehicle or trailer, and automatically activate the alarm, increase the touchscreen brightness and play music at max volume if a threat is detected,” Tesla writes on the Cybertruck page.

The music feature could use the Cybertruck’s superhorn and external speaker to play the music outside the vehicle for an even louder response to potential threats, though it’s not clear at this point whether the added feature will utilize the external or internal speakers. The music feature is also not detailed on Tesla’s web pages for other vehicles at this point, though it would be surprising to see it only available on the Cybertruck given that Sentry Mode is available across the company’s entire lineup.

You can also see the Sentry Mode image that appears on the touchscreen when activated below.

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Credit: Tesla

READ MORE ON TESLA SENTRY MODE: Tesla is about to ship a fix to a big Sentry Mode issue

Tesla details the features from Sentry Mode in its owner’s manuals as follows:

When enabled, your vehicle’s cameras remain powered on and ready to record suspicious activity around your vehicle when Cybertruck is locked and in Park. Think of Sentry Mode as an intelligent vehicle security system that alerts you when it detects possible threats nearby.

If a threat is detected or the vehicle sensors determine there is a lot of jerky movement like when getting towed or shaken, Sentry Mode:

    • Pulses the headlights.
    • Sounds the alarm.
    • Displays a message on the touchscreen that indicates cameras may be recording to inform individuals outside of the vehicles.
    • Alerts you of the alarm on the mobile app.
    • Saves footage of the event to a USB drive (if installed)

Earlier this week, CEO Elon Musk also said that Tesla was increasing security at the company’s stores, along with activating Sentry Mode on all vehicles at the company’s locations. Musk also said earlier this month that it could make its vehicles automatically honk at people who come near or touch the vehicle, which would take a similar approach to scaring off people potentially keying or otherwise vandalizing a Tesla.

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Following a substantial uptick in protests and vandalism targeting Tesla’s vehicles in response to Musk’s recent actions at Trump’s inauguration and since with the newly created government efficiency, the Federal Bureau of Investigation (FBI) has begun looking into several of these incidents.

Additionally, President Donald Trump said that Tesla attacks would be categorized as “domestic terrorism,” even suggesting that some of those who have been recently arrested in these cases could be sent to prison camps in El Salvador, where the administration has recently been sending migrants.

“I look forward to watching the sick terrorist thugs get 20 year jail sentences for what they are doing to Elon Musk and Tesla,” Trump wrote in a post on his social media platform Truth Social. “Perhaps they could serve them in the prisons of El Salvador, which have become so recently famous for such lovely conditions!”

Could Tesla vandalism fuel higher insurance prices?

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