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Tesla Model X cited as “most significant vehicle”, by growth contribution to record 2016 PEV sales

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Electric and plug-in hybrid car sales established new sales records in 2016 with the Tesla Model X earning the title of “most significant vehicle” according to EV Volumes. The industry tracking site cites the Model X for its contribution to the growth of plug-in car sales in the US this past year.

EV Volumes defines any car with a plug as a plug-in, which may cause some Tesla fans heartburn. The site does acknowledge that plug-in hybrids are probably a stop-gap solution until there are more pure electric cars with at least 200 miles of range available to American consumers.

“The volume increase in 2016 can be attributed to Tesla (+95 % for S & X combined), the new GM Volt (+61 %), Ford Fusion (+63 %) and a number of newcomers, mostly in the Plug-in Hybrid category.” indicates the published report. “By its growth contribution, the Tesla Model X must be regarded the most significant vehicle this year.”

The Tesla Model S was the overall sales leader for the year with 28,821 units sold to US customers, a 22% increase over 2015. The Model X finished the year with 17,629 US sales, good enough for 3rd place overall. The second generation Chevy Volt claimed 2nd place with 24,739 cars delivered to customers in the US, a 61% increase.

US plug-in car sales since January, 2011. Source: ZEV Facts by Alliance of Automobile Manufacturers

California claimed nearly 50% of all plug-in sales with the other 9 states that adhere to the California zero emissions standards accounting for another 13%. Combined, all ten states accounted for nearly 62% of all US plug-in sales. In the conventional car market, those states make up about 28% of the US new car market.

Other cars with plugs that sold more than 10,000 units in the US in 2016 include the Ford Fusion Energi plug-in hybrid, which saw its sales grow 63% last year to almost equal the Tesla Model X in total sales. The Fusion Energi now accounts for about 10% of all Fusion sales, despite the fact that Ford CEO Mark Fields insists that nobody wants to buy electric cars.

Sales of the Fusion Energi took off midyear after Ford began to advertise it as the longest range plug-in hybrid available. That claim is technically accurate — the Fusion Energi can travel more than 600 miles on a tank of fuel. But it is misleading in that the car only has 22 miles of range on battery power alone, which is only fair to middling for a plug-in hybrid these days.

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To give the Fusion Hybrid more range, Ford simply increased the size of the gas tank. All of which suggests that the buying public is still woefully uninformed about cars with plugs, just as Elon Musk always claims when he talks about what a poor job car companies and automobile dealers do marketing electric cars.

The last car to sell more than 10,000 units last year is the venerable Nissan LEAF. Although Nissan promises an all new second generation LEAF with 200 miles or more of range sometime before the end of 2019, the current car is hopelessly out of date. It is essentially the same as it was when it first went on sale at the end of 2010. Still, the LEAF soldiered on to sell just over 14,000 cars in the US last year.

2016 Plug-in car sales in the US. Source: EV Volumes

In all, more than 156,000 cars with plugs were sold in the US in 2016. EV Volumes predicts that number will climb to 250,000 or more in 2017, assuming at least 50,000 Tesla Model 3 sedans are included. Whether the Model 3 makes it to market in significant numbers is one of the biggest stories industry watchers will be following this year.

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

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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

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Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

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Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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