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Tesla Model Y’s front impact structure opens doors to a stellar safety rating
Sandy Munro’s newest video of his Model Y teardown series included a breakdown of the electric crossover’s revised front impact structure. Most notably, Munro’s analysis of the improved impact structure on the Model Y could make Tesla’s reputation for producing some of the safest cars on the market even more solidified, as the thicker and sturdier elements in the all-electric crossover could pave the way for another stellar safety rating.
When Elon Musk unveiled the Model Y in March 2019, he stated that “We expect it will be the safest midsize SUV in the world by far,” he said. The numerous safety improvements that have been recognized by Munro are vital indicators that Musk may be right, and the Model Y could prove itself to be one of, if not the safest car in its class in the market.
As the Model Y’s performance features have already been broken down by many, the safety features are among the more elusive details of the vehicle. Munro notes the Model Y contains several improved features compared to the Model 3, which already holds a five-star safety rating. The first described addition to the Model Y’s safety “system” is the increased thickness of the sheet metal at the front of the rail, as seen in the image below.
This addition will improve the front-end collision system of the vehicle, which was already impressive on the Model 3. However, Tesla is dealing with a more massive vehicle that maintains a different body structure, and beefing up the parts in the front end of the car was one of the ways the company could make the Model Y safer.
Next, Munro points out Tesla’s revisions to the front cradle. The cradle is a subframe structural component that is separate from the larger and “primary” chassis on a vehicle. It is usually used to carry engines, drivetrains, suspension systems, or in the case of the Model Y, its front end impact structure.
The Model Y’s front cradle holds the front impact structure as the two are “tied” together, Munro states. This cradle mounting points to the vehicle’s mainframe extend well into the vehicle’s Small Overlap Rigid Barrier, or SORB zone. The more rigid, dense, sturdy, and durable cradle and front rail increase the safety of the vehicle if it collides with a pole, tree, or another car. These are among some of the most dangerous types of accidents, according to the IIHS.
Tesla also added what Munro refers to as a “tusk” just behind the front quarter panels of the Model Y. The tusk is designed to collapse into the vehicle’s longitudinals. This energy will then be transferred to the now-thicker front end rail in the event of a front side collision, diverting energy from a violent accident away from the passenger cabin. “The tusk will fold in, and it’s going to smash into the longitudinals, and probably other things. That’s going to start to put the energy from the event into the structure here (referring to the front rail), that is uber-strong,” Munro says.
Munro says the structure is entirely different than what Tesla used on the Model 3, citing the new build seems to be exceptionally safe and improved. Interestingly enough, the Model 3 was already recognized as one of the safest vehicles on the road and has received top marks from the Insurance Institute for Highway Safety (IIHS) and Euro NCAP, among others. Despite the impressive and proven safety of the Model 3, it appears that Tesla wanted to do even better. The Model Y is a tangible representation of it.
Watch Sandy Munro breakdown Tesla Model Y’s front end impact system in the video below.
News
Tesla Robotaxi rival Waymo confirms massive fleet expansion in Bay Area
New data from the California Public Utilities Commission (CPUC) said Waymo had 1,429 vehicles operating in California, and 875 of them were “associated with a terminal in San Francisco,” according to The SF Examiner.
Tesla Robotaxi rival Waymo has confirmed that it has expanded its fleet of driverless ride-sharing vehicles in the Bay Area of California massively since its last public disclosure.
It is perhaps one of the most important metrics in the race for autonomous supremacy, along with overall service area. Tesla has seemed to focus on the latter, while expanding its fleet slowly to maintain safety.
Waymo, on the other hand, is bringing its fleet size across the country to significant levels. In March, it told The SF Examiner that there were over 300 Waymos in service in the San Francisco area, which was not a significant increase from the 250 vehicles on the road it reported in August 2023.
In May, the company said in a press release that it had more than 1,500 self-driving Waymos operating nationwide. More than 600 were in the San Francisco area.
Tesla analyst compares Robotaxi to Waymo: ‘The contrast was clear’
However, new data from the California Public Utilities Commission (CPUC) said Waymo had 1,429 vehicles operating in California, and 875 of them were “associated with a terminal in San Francisco,” according to The SF Examiner.
CPUC data from March 2025 indicated that there were a total of 1,087 Waymo vehicles in California, with 762 located in San Francisco. Some were test vehicles, others were deployed to operate as ride-sharing vehicles.
The company’s August update also said that it deploys more than 2,000 commercial vehicles in the United States. That number was 1,500 in May. There are also roughly 400 in Phoenix and 500 in Los Angeles.
While Waymo has done a good job of expanding its fleet, it has also been able to expand its footprint in the various cities it is operating in.
Most recently, it grew its geofence in Austin, Texas, to 90 square miles. This outpaced Tesla for a short period before the company expanded its Robotaxi service area earlier this week to roughly 170 square miles.
Tesla one-ups Waymo once again with latest Robotaxi expansion in Austin
The two companies have drastically different approaches to self-driving, as Waymo utilizes LiDAR, while Tesla relies solely on cameras for its suite. Tesla CEO Elon Musk has made no mistake about which he believes to be the superior solution to autonomy.
News
Tesla launches Full Self-Driving in a new region
Today, Tesla launched Full Self-Driving in Australia for purchase by car buyers for $10,100, according to Aussie automotive blog Man of Many, which tried out the suite earlier this week.
Tesla has launched its Full Self-Driving suite in a new region, marking a significant step in the company’s progress to expand its driver assistance suite on a global scale.
It is also the first time Tesla has launched FSD in a right-hand-drive market.
Today, Tesla launched Full Self-Driving in Australia for purchase by car buyers for $10,100, according to Aussie automotive blog Man of Many, which tried out the suite earlier this week.
Previously, Basic and Enhanced Autopilot suites were available, but the FSD capability now adds Traffic Light and Stop Sign Control, along with all the features of the previous two Autopilot suites.
🚨 Tesla has officially launched Full Self-Driving in Australia for the price of $10,100 outright.
The move marks a significant step in Tesla’s progress to expand the suite on a global scale pic.twitter.com/zzHa8Ngqls
— TESLARATI (@Teslarati) August 28, 2025
It is the first time Tesla has launched the suite by name in a region outside of North America. In China, Tesla has “City Autopilot,” as it was not permitted to use the Full Self-Driving label for regulatory reasons.
However, Tesla still lists Full Self-Driving (Supervised) as available in the U.S., Canada, China, Mexico, and Puerto Rico.
The company teased the launch of the suite in Australia earlier this week, and it appeared to have been released to select media members in the region earlier this week:
Tesla FSD upcoming Australia release seemingly teased bv media
The rollout of Full Self-Driving in the Australian market will occur in stages, as Model 3 and Model Y vehicles with Hardware 4 will receive the first batch of FSD rollouts in the region.
TechAU also reported that “the initial deployment of FSDs in Australia will roll out to a select number of people outside the company, these people are being invited into Tesla’s Early Access Program.”
Additionally, the company reportedly said it is “very close” to unlocking FSD in customer cars:
BREAKING: Tesla has officially announced that FSD (Supervised) is launching in Australia, marking a huge milestone for the company.
The rollout will happen in stages. HW4 Model 3s and Model Ys will get it first. Tesla says it is “very close” to being unlocked in customer cars.… pic.twitter.com/r1dYnFRa6o
— Sawyer Merritt (@SawyerMerritt) August 28, 2025
Each new Tesla sold will also come with a 30-day free trial of the suite.
Australia is the sixth country to officially have Full Self-Driving available to them, following the United States, Canada, China, Mexico, and Puerto Rico.
Here’s the first look at the suite operating in Australia:
News
Tesla AI6 chips will start sample production at surprising Samsung site
AI6 is expected to be used in Tesla’s expanding lineup of high-volume products, such as the Cybercab and Optimus.
It appears that the initial sample production of Tesla’s next-generation AI6 chip would not start in Samsung’s United States-based facilities.
AI6 is expected to be used in Tesla’s expanding lineup of high-volume products, such as the Cybercab and Optimus.
Early AI6 production
As noted in a ZDNet Korea report, the production of initial samples of Tesla’s AI6 chip is expected to start at Samsung Electronics’ domestic foundry and packing facilities in South Korea. Mass production for AI6 chips will follow at the tech giant’s Texas-based foundry in Taylor, which is expected to start operations in 2025. Investment in mass production facilities for the Taylor plant are expected to start this year, the publication noted.
Samsung has reportedly finalized the process design kit for its second-generation 2nm technology. This node offers a 12% performance improvement, 25% lower power consumption, and an 8% reduction in chip area compared to its previous-generation counterparts.
Tesla’s AI6 deal
As per previous reports, Tesla has signed a $16.5 billion contract with Samsung for the production of its AI6 chips. In a post on social media platform X, Musk clarified that $16.5 billion is actually just the bare minimum. Considering that the demand for AI6 chips will be substantial due to the ramp of products such as Optimus and the Cybercab, it would not be farfetched if the deal becomes notably larger in the future.
Musk has shared his excitement for Samsung’s production of AI6 chips, with the CEO stating on X that he would “walk the line personally” in the facility to “accelerate the pace of progress.” In a follow-up comment, the Tesla CEO stated that Samsung is fully aware of what a real partnership with Tesla will be like. “I had a video call with the chairman and senior leadership of Samsung to go over what a real partnership would be like. Use the strengths of both companies to achieve a great outcome,” Musk wrote in his post.
Tesla Robotaxi rival Waymo confirms massive fleet expansion in Bay Area
Tesla launches Full Self-Driving in a new region
Tesla AI6 chips will start sample production at surprising Samsung site
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