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[UPDATE] Tesla Model S Struck By Lightning While Charging

A Model S disabled by lightning while charging must wait at least one day for Tesla technicians to figure out what went wrong and restore it to service.

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UPDATED June 6

It’s been a week since Sarah Day’s Model S got struck by lightning while she was at a SuperCharger facility. So far, she reports Tesla really has no idea what happened to her car, but the technicians at the local Tesla Service Center have been kept busy trying to repair it.

She understands the battery has been removed and sent off to the factory in California, where Tesla engineers “are almost giddy to get their hands on it,” she says. Apparently this is a first of its kind event and the company is putting every effort into trying to understand what happened. Sarah has been told that there may be an official announcement from Tesla when they get it all figured out.

In the meantime, she says “All eyes are on Columbus.” The incident occurred in Ohio, not Georgia as I originally thought. She has asked to be provided with a full technical analysis of what happened to her car and what it will take to fix it when that information becomes available.

For now, there seems to be no correlation between the lightning strike and the fact that her car was charging at the time. It seems Sarah was just unlucky that the lightning came so close. It may be cool to be the center of attention at Tesla headquarters for a little while, but I think by now she would prefer to have her car back so she can get on with her life.

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A Model S struck by lightning while charging will have to wait at least one day for Tesla technicians to bring it back to life and figure out what happened. Sarah Day was charging her Tesla Model S at a Supercharger location near Columbus, Georgia [Edit: The location of the event occurred at Columbus, OH and not Columbus, GA as originally published] on Sunday morning when a lightning bolt hit very close by. Her first indication that something was wrong came when her BlackVue dash cam lost power. Here’s how she describes what happened next:

“I heard the crash, and just a second or two after about 9 errors popped up on the dashboard. Some of them were low charge warnings, saying it would disable some functions. Others were on how the car needs to be serviced. I was also getting that the car can’t be charged, and that the 12 volt battery is low.

“After the storm died down I got out of the car. The charging port wasn’t lit up, and when I tried to remove the cable it wouldn’t come out. I still had most of the functions in the car, including the touchscreen. The other car that was charging just a couple stalls down from me was completely fine and drove away, though I didn’t get to talk to that owner afterwards.”

Sarah called Tesla but had trouble getting through due to high call volume. The company agreed to send a tow truck, but before it got there, the 12 volt battery failed and the touchscreen shut down. When the tow driver arrived, he attempted to charge up the battery but it took two attempts before the touchscreen came back to life. Even then, the charging cable still would not disconnect from the car. Sarah couldn’t get the sunroof to close, either.

Since the car couldn’t be towed with the charging cable connected, Sarah had to leave her car at the Supercharger station with the sunroof partially open. There was nothing more she could do until the local Tesla service station opened for business on Monday morning.

Although Sarah wasn’t happy about her car being disabled, she can’t say enough good things about Tesla service and support people who took her phone calls.

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“Tesla customer service was amazing. They were very responsive, and offered to rent me a car from enterprise so I could come home. I said I would rather stay with the car for a couple days to see how it all played out. I am from Atlanta and I was visiting a friend in Columbus, and I didn’t want to be that far away from the car in case of any issues.

“They offered to put me up in a hotel for a night, and also to get me a taxi or Uber ride. I decided I’d just stay with my friend, but they sent the Uber driver over for me. Also, the service center in Marietta, GA has been in contact with me to see how things are going. I know them pretty well, as well as one of the technicians. They have been incredibly helpful and supportive, though they can’t really do anything from there.”

The local Tesla service center will send a technician Monday morning to get the charging cable disconnected and bring the car in to be checked over. Sarah was told that each Supercharger has multiple relays and sensors to protect the cars from surges. At this point, she has no explanation for why her car was disabled, but expects a full report on Monday. She has complete confidence in Tesla service personal to identify the problem and get her car functioning properly again.

“They usually are pretty thorough with their descriptions of what went wrong. I’m hoping that it’s something simple. The technician in Marietta says the car may have sensed the large external voltage spike and disconnected everything as a safety precaution, but I don’t know if that would cause the charging port to malfunction.”

Thanks to Sarah Day for sharing with us details of her experience while she was in the middle of being stranded far from home. We will update this report when more information becomes available.

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"I write about technology and the coming zero emissions revolution."

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Investor's Corner

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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Investor's Corner

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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