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Tesla Model Y manufacturing improvements highlighted in published patent application
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.”
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- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
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- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
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- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
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- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
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.
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.
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IM Motors co-CEO apologizes to Tesla China over FUD comments
Liu said later investigations showed the accident was not caused by a brake failure on the Tesla’s part, contrary to his initial comments.
Liu Tao, co-CEO of IM Motors, has publicly apologized to Tesla China for comments he made in 2022 suggesting a Tesla vehicle was defective following a fatal traffic accident in Chaozhou, China.
Liu said later investigations showed the accident was not caused by a brake failure on the Tesla’s part, contrary to his initial comments.
IM Motors co-CEO issues apology
Liu Tao posted a statement addressing remarks he made following a serious traffic accident in Chaozhou, Guangdong province, in November 2022, as noted in a Sina News report. Liu stated that based on limited public information at the time, he published a Weibo post suggesting a safety issue with the Tesla involved in the crash. The executive clarified that his initial comments were incorrect.
“On November 17, 2022, based on limited publicly available information, I posted a Weibo post regarding a major traffic accident that occurred in Chaozhou, suggesting that the Tesla product involved in the accident posed a safety hazard. Four hours later, I deleted the post. In May 2023, according to the traffic police’s accident liability determination and relevant forensic opinions, the Chaozhou accident was not caused by Tesla brake failure.
“The aforementioned findings and opinions regarding the investigation conclusions of the Chaozhou accident corrected the erroneous statements I made in my previous Weibo post, and I hereby clarify and correct them. I apologize for the negative impact my inappropriate remarks made before the facts were ascertained, which caused Tesla,” Liu said.
Investigation and court findings
The Chaozhou accident occurred in Raoping County in November 2022 and resulted in two deaths and three injuries. Video footage circulated online at the time showed a Tesla vehicle accelerating at high speed and colliding with multiple motorcycles and bicycles. Reports indicated the vehicle reached a speed of 198 kilometers per hour.
The incident drew widespread attention as the parties involved provided conflicting accounts and investigation details were released gradually. Media reports in early 2023 said investigation results had been completed, though the vehicle owner requested a re-investigation, delaying the issuance of a final liability determination.
The case resurfaced later in 2023 following a defamation lawsuit filed by Tesla China against a media outlet. According to a court judgment cited by Shanghai Securities News, forensic analysis determined that the fatal accident was unrelated to any malfunction on the Tesla’s braking or steering systems. The court also ruled that the media outlet must publish an apology, address the negative impact on Tesla China’s reputation, and pay a penalty of 30,000 yuan.
Elon Musk
SpaceX is exploring a “Starlink Phone” for direct-to-device internet services: report
The update was reportedly shared to Reuters by people familiar with the matter.
SpaceX is reportedly exploring new products tied to Starlink, including a potential Starlink-branded phone.
The update was reportedly shared to Reuters by people familiar with the matter.
A possible Starlink Phone
As per Reuters’ sources, SpaceX has reportedly discussed building a mobile device designed to connect directly to the Starlink satellite constellation. Details about the potential device and its possible release are still unclear, however.
SpaceX has dabbled with mobile solutions in the past. The company has partnered with T-Mobile to provide Starlink connectivity to existing smartphones. And last year, SpaceX initiated a $19.6 billion purchase of satellite spectrum from EchoStar.
Elon Musk did acknowledge the idea of a potential mobile device recently on X, writing that a Starlink phone is “not out of the question at some point.” Unlike conventional smartphones, however, Musk described a device that is “optimized purely for running max performance/watt neural nets.”
Starlink and SpaceX’s revenue
Starlink has become SpaceX’s dominant commercial business. Reuters’ sources claimed that the private space company generated roughly $15–$16 billion in revenue last year, with about $8 billion in profit. Starlink is estimated to have accounted for 50% to 80% of SpaceX’s total revenue last year.
SpaceX now operates more than 9,500 Starlink satellites and serves over 9 million users worldwide. About 650 satellites are already dedicated to SpaceX’s direct-to-device initiative, which aims to eventually provide full cellular coverage globally.
Future expansion of Starlink’s mobile capabilities depends heavily on Starship, which is designed to launch larger batches of upgraded Starlink satellites. Musk has stated that each Starship launch carrying Starlink satellites could increase network capacity by “more than 20 times.”
Elon Musk
FCC accepts SpaceX filing for 1 million orbital data center plan
The move formally places SpaceX’s “Orbital Data Center” concept into the FCC’s review process.
The Federal Communications Commission (FCC) has accepted SpaceX’s filing for a new non-geostationary orbit (NGSO) satellite system of up to one million spacecraft and has opened the proposal for public comment.
The move formally places SpaceX’s “Orbital Data Center” concept into the FCC’s review process, marking the first regulatory step for the ambitious space-based computing network.
FCC opens SpaceX’s proposal for comment
In a public notice, the FCC’s Space Bureau stated that it is accepting SpaceX’s application to deploy a new non-geostationary satellite system known as the “SpaceX Orbital Data Center system.” As per the filing, the system would consist of “up to one million satellites” operating at altitudes between 500 and 2,000 kilometers, using optical inter-satellite links for data transmission.
The FCC notice described the proposal as a long-term effort. SpaceX wrote that the system would represent the “first step towards becoming a Kardashev II-level civilization – one that can harness the Sun’s full power.” The satellites would rely heavily on high-bandwidth optical links and conduct telemetry, tracking, and command operations, with traffic routed through space-based laser networks before being sent to authorized ground stations.
FCC Chairman Brendan Carr highlighted the filing in a post on X, noting that the Commission is now seeking public comment on SpaceX’s proposal. Interested parties have until early March to submit comments.
What SpaceX is proposing to build
As per the FCC’s release, SpaceX’s orbital data center system would operate alongside its existing and planned Starlink constellations. The FCC notice noted that the proposed satellites may connect not only with others in the new system, but also with satellites in SpaceX’s first- and second-generation Starlink networks.
The filing also outlined several waiver requests, including exemptions from certain NGSO milestone and surety bond requirements, as well as flexibility in how orbital planes and communication beams are disclosed, as noted in a Benzinga report. SpaceX noted that these waivers are necessary to support the scale and architecture of the proposed system.
As noted in coverage of the filing, the proposal does not represent an immediate deployment plan, but rather a framework for future space-based computing infrastructure. SpaceX has discussed the idea of moving energy-intensive computing, such as AI workloads, into orbit, where continuous solar power and large physical scale could reduce constraints faced on Earth.
IM Motors co-CEO apologizes to Tesla China over FUD comments
SpaceX is exploring a “Starlink Phone” for direct-to-device internet services: report
