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Tesla Model Y manufacturing improvements highlighted in published patent application

Tesla's next-gen Roadster and the Model Y at the 2019 Annual Shareholder Meeting. (Photo: Vincent Yu/Twitter)

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In an effort to continue streamlining its manufacturing process, Tesla has developed a new vehicle frame casting machine. The specifics are described in a patent application published on July 18, 2019 titled, “Multi-Directional Unibody Casting Machine for a Vehicle Frame and Associated Methods.” CEO Elon Musk previously referred to such a machine that was under development during his conversation with Ryan McCaffrey of the Ride the Lightning podcast in June. His comments at the time were in reference to manufacturing improvements being made specifically for Model Y production.

“There are some manufacturing improvements for the [Model] Y. The rear underbody we’re moving to an aluminum…casting instead of a series of stamped steel and aluminum pieces,” Musk revealed in the interview. “When we get the big casting machine, it’ll go from 70 parts to 1 with a significant reduction in capital expenditure on all the robots to put those parts together.”

As described, Tesla’s new casting machine will have a central hub to receive several dies that are assembled into specific portions of a vehicle frame before being cast. The dies can transform into multiple configurations along the X, Y, and Z axis, essentially forming into numerous part molds. Further suggested by the patent application is that a full car frame may be made with a single cast using these transforming capabilities.

Casting molds are common in car manufacturing; however, single part molds are often what’s used, and bolts and welding are then subsequently required. A single casting machine configurable for several parts has many advantages, including reduced build time, operation costs, manufacturing costs, factory footprint, tooling costs, and equipment quantity. Using a casting machine for the Model Y will also reduce the weight of the all-electric crossover, according to Musk. Battery efficiency will be positively impacted by a lighter vehicle with only an 8-10% impact on range expected in the Model Y when compared to the Model 3.

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Anticipation for the Model Y is building despite few details being revealed by Tesla since its unveiling in March. During the California-based car maker’s annual shareholder meeting this year, a red working prototype of the vehicle was on display alongside a next generation Roadster and a Tesla Semi, both also red. Prior to the event, only blue and white versions had been revealed, the blue having been used for test drives at its unveiling.

The manufacturing location for the Model Y also has yet to be announced, although Tesla’s Fremont factory looks to be the most likely candidate. Production is still anticipated for 2020.

Accidental computer geek, fascinated by most history and the multiplanetary future on its way. Quite keen on the democratization of space. | It's pronounced day-sha, but I answer to almost any variation thereof.

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Tesla gathers Cybercab fleet in Gigafactory Texas

Images and video of the Cybercab fleet were shared by longtime Giga Texas observer Joe Tegtmeyer in posts on social media platform X.

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Credit: Credit: @JoeTegtmeyer/X

Tesla appears to be assembling a growing number of Cybercabs at Gigafactory Texas as preparations continue for the vehicle’s mass production. Recent footage shared online has shown over 30 Cybercabs being transported by trucks or staged near testing areas at the facility.

The images and video were shared by longtime Giga Texas observer and drone operator Joe Tegtmeyer in posts on social media platform X.

Interestingly enough, Tegtmeyer noted that many of the Cybercabs being loaded onto transport trucks were still equipped with steering wheels. This suggests that the vehicles are likely testing units rather than the final driverless configuration expected for the company’s Robotaxi service.

The vehicles could potentially be headed to testing sites across the United States as Tesla prepares to expand its Robotaxi fleet.

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Additional footage captured at Gigafactory Texas also showed the Cybercab’s side and rear camera washer system operating as vehicles were being loaded onto transport trucks.

The growing number of Cybercabs at Giga Texas comes amidst the company’s announcement that the first production Cybercab has been produced at the facility. Full Cybercab production is expected to begin in April.

The vehicle is expected to play a central role in Tesla’s Robotaxi ambitions as the company looks to expand autonomous ride-hailing operations beyond its early deployments using Model Y vehicles.

Tesla has also linked Cybercab production to its proposed Unboxed manufacturing process, which assembles large vehicle modules separately before integrating them. The approach is intended to reduce production costs and accelerate output.

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Musk has also noted that the Cybercab’s ramp will likely begin slowly due to the number of new components and manufacturing steps involved. However, he stated that once the process matures, Cybercab production could scale quickly.

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Elon Musk’s xAI, creator of Grok and Grokipedia, celebrates its third birthday

xAI Memphis highlighted several of its milestones over the years in its celebratory post. 

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Credit: xAI

Elon Musk’s artificial intelligence startup xAI has marked its third anniversary. The update was shared in a post from the xAI Memphis account on social media platform X.

xAI Memphis highlighted several of its milestones over the years in its celebratory post

As per xAI, it has built three massive data centers in the city, launched a coherent cluster of 330,000 GBs, created over 3,000 jobs, and paid over $30 million in taxes to local communities.

xAI’s Memphis operation has become a key part of the company’s infrastructure as the company works to train and deploy its Grok artificial intelligence models. Elon Musk has been quite optimistic about Grok’s potential, noting in the past that the large language model might have a shot at achieving artificial general intelligence (AGI). 

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xAI’s Memphis’ crown jewel is its Colossus supercomputer cluster. The project was announced in 2024 and has since become the home of one of the world’s largest AI compute facilities. The first phase of Colossus reached its initial 100,000 GPU operational milestone in just 122 days, or just about four months.

Industry figures such as Nvidia CEO Jensen Huang have praised the facility, noting that projects of similar scale typically take two to four years to complete.

xAI has cited Memphis’ central location, skilled workforce, and industrial infrastructure as key reasons for selecting the city as the home of its AI training operations. The company has also emphasized plans to expand the site further as it scales compute capacity for Grok and future AI models.

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Tesla Sweden’s Megapack Supercharger near Arlanda continues to aggravate IF Metall union

The charging site, located in Arlandastad outside Stockholm, appears to be operating despite ongoing union blockade measures tied to Tesla’s labor dispute in the country.

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Credit: Tesla Charging/X

Tesla Sweden’s Megapack-powered Supercharger station near Arlanda Airport has continued to aggravate Swedish labor union IF Metall. The charging site, located in Arlandastad outside Stockholm, appears to be operating despite ongoing union blockade measures tied to Tesla’s labor dispute in the country.

Comments about the site were shared by IF Metall representatives in remarks to Swedish publication CarUp.

The Arlandastad location includes eight Tesla Superchargers powered by a Megapack battery system. Unlike traditional charging stations that rely on direct grid connections, the site uses a large battery installation to store electricity and power the chargers.

According to the Swedish publication, the setup allowed the station to come online despite sympathy measures from Sweden’s electricians’ union, which has attempted to prevent companies from cooperating with Tesla as part of the broader labor conflict.

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IF Metall press manager Jesper Pettersson indicated that the union was not aware that the Superchargers had already been connected and activated.

“We do not know the details around this. But it is further proof of how Tesla systematically finds loopholes to circumvent the sympathy measures through active strikebreaking. Every time this happens it gives us reason to sharpen our conflict measures,” Pettersson said.

Union representatives also noted that the Megapack appears to be charged using electrical cables routed through nearby terrain, though the exact power source remains under review.

The Megapack-powered site has then prompted questions from Swedish labor unions about how electricity is being supplied to the system.

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IF Metall has submitted a report to Sweden’s Energy Market Inspectorate asking the regulator to review whether the electricity supply arrangement complies with national regulations. The Megapack is reportedly charged using electricity from a local company, though the provider has not been publicly identified.

Peter Lydell, an ombudsman at IF Metall, previously stated that Swedish law limits electricity trading to companies with proper authorization.

“The legislation states that only companies that engage in electricity trading may supply electricity to other parties. You may not supply electricity without a permit, then you are engaging in illegal electricity trading. That is why we have reported this… 

“This is about a company that helps Tesla circumvent the conflict measures that exist. It is clear that it is troublesome and it can also have consequences,” Lydell said.

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IF Metall and Tesla Sweden’s conflict has been going on for over two years now. 

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