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Tesla’s sure-footed Model Y approach is the crossover market’s ultimate Trojan Horse

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The future of the crossover market may have already started changing–the auto industry has just not realized it yet. Signs of this shift could be found beneath the surface of the Tesla Model Y, a crossover that represents the years of experience in vehicle making that the Silicon Valley-based company gained since it started building cars over a decade ago. 

The Model Y could almost be described as Tesla’s most unassuming vehicle based on its exterior. Featuring a very similar design as the Model 3 and lacking the flashy features of the Model X, the Model Y looks very understated. This is one of the reasons why it was so easy for critics to dismiss the Model Y. Some, on account of the crossover’s Model 3-based design during its unveiling, even flat-out insisted that the Model Y does not exist

The Model Y is currently undergoing a thorough teardown and analysis from automotive specialist Sandy Munro of Munro and Associates. The progress of the Model Y teardown has been incremental due to the ongoing pandemic, but the sections of the vehicle that have already undergone analysis all show one theme: the Model Y is the representation of Tesla’s refinements to its vehicle production process over the years, regardless of how minor they might be. 

This could be seen in a comparison of the Model Y and the Model 3’s headliner. A look at the first-production Model 3’s headliner shows that Tesla seemed to have gone for a more traditional approach for the component, such as using glue to set specific parts in position. Tesla used a more unique injection-molded headliner for the Model Y, which eliminates the need for much of the glue used in the Model 3’s component. A hefty dose of Noise, Vibration, and Harshness (NVH) countermeasures were also found on the crossover. Overall, the Model Y shows a far more sure-footed Tesla, one that has solid experience in carmaking. 

The Tesla Model Y shares 75% of the Model 3’s parts. (Credit: @nate_mccomb/Twitter)

Elon Musk has noted on Twitter that teardown experts like Munro will likely find many pleasant surprises in the Model Y, and so far, this does seem to be the case. While the vehicle still has areas for improvement, the fact remains that the crossover, which is still in its first production, is already far more refined than its predecessor. From its novel Octovalve system to its use of rigid wiring that can be set by robots on a fully-automated line, the Model Y seems to be Tesla’s most forward-thinking vehicle yet. And this could make all the difference. 

The Model Y is competing in the crossover segment, which is highly competitive but incredibly lucrative. Just like the pickup truck market, there are vehicles that have become legends in the crossover industry, from affordable entries such as the Toyota RAV4 to premium SUVs like the Porsche Macan. The Model Y is designed to compete in this market and offer potential customers a compelling alternative to tried and tested vehicles. Considering its price, its tech, and the fact that it seems to be designed very well, the Model Y will likely have more than a fighting chance to compete. 

Tesla has a habit of making a vehicle that ends up becoming a Trojan horse of sorts. The Model 3 is one of these, as the car ended up disrupting the midsize premium sedan market to such a degree that sales of rivals like the BMW M3 have been decimated, despite critics largely dismissing Tesla in the lead up to its release. But unlike the Model 3’s first production units, even the Model Y’s first run already shows a certain degree of maturity in vehicle design and manufacturing. The Model Y will only get better with time as Tesla continues to refine little aspects of the vehicle, but even at its current state, the all-electric crossover is already something that is out of the ordinary. 

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And that is the biggest irony of all. Legacy automakers appear to have adopted a pretty dismissive approach to the Model Y. Save for Ford, which has unveiled the Mustang Mach-E, and Porsche, which has announced an all-electric Macan, the premium all-electric crossover market seems strangely open for domination. Just like with the Model 3, legacy auto appears to be all-too-willing to make way for the Model Y. And just as before, by the time competitors realize the all-electric crossover’s true potential, there is a very good chance that they will be late, just as the Model 3’s rivals like the BMW i4 are late today. 

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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.

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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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.

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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