

News
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.”
- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
- US Patent Publication No. 20190217380 | Image: Tesla/USPTO
- 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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U.S. Secret Service in talks on armored cars with this automaker
The Secret Service says it’s still too early to know the future of a potential deal for these “highly-advanced vehicles.”

The U.S. Secret Service has entered early discussions with one automaker about the potential supply of armored SUVs, as announced by the agency this week.
In a post on X on Friday, the Secret Service account posted that Director Sean Curran recently met with executives from General Motors (GM) to discuss a potential next-generation of armored SUVs. The post also included photos of a Cadillac Escalade SUV, along with a few of executives talking about and showing off hardware from the next-gen platform.
“Countering evolving threats require us to constantly explore new innovations and improvements to our armored fleet of protective vehicles,” the account wrote in the post. “Director Sean Curran met with GM executives to discuss advancements that could benefit the next generation of armored SUVs.”

Credit: U.S. Secret Service | X

Credit: U.S. Secret Service | X
Currently, U.S. President Donald Trump typically utilizes an armored Chevy Suburban to get around, and the Secret Service said that it isn’t yet clear when such a next-gen “presidential limousine” could be added to the fleet. The news also comes after GM CEO Mary Barra met with Trump last week, reportedly also to discuss armored SUVs.
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“We are too far out to speak to any specific costs or dates,” one Secret Service spokesperson told Reuters. “Our engineering, protective operations and technical security teams work for years to develop the state-of-the-art framework that is used to produce these highly advanced vehicles.”
Many in the thread also said that the Tesla Cybertruck could be a good option for the Secret Service, coming weeks after the U.S. State Department apparently canceled a potential $400 million Cybertruck order after it was widely reported on. State Department officials have since said that the figure listed in documents for the deal, which was first initiated under the Biden administration, were simply an estimate, and the Cybertruck has been removed from the broadly reported procurement list.
CEO Elon Musk also responded to the reports on X, suggesting that they were either misunderstood or false, noting that he was “pretty sure Tesla isn’t getting $400 million.”
“No one mentioned it to me, at least,” Musk added in the post.
The Cybertruck features a stainless steel exterior that has been touted by Tesla as being able to withstand bullets and other potential attacks. Tesla Cybertrucks have also been rolling out to some U.S. Police Departments in recent months, many featuring armored tune-ups from Unplugged Performance’s Up.Fit government and military fleet division.
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Tesla Powerwalls to help expand Virtual Power Plant in Colorado
Colorado’s Virtual Power Plant program is about to get even bigger, with the help of Tesla’s Powerwalls.

Tesla’s Powerwalls are set to help expand a Virtual Power Plant (VPP) program in Colorado, as an announcement this week notes that the company will be partnering with two local energy providers.
In a press release on Thursday, utility provider Xcel Energy and resource management company Itron announced a partnership with Tesla to help expand the existing VPP in Colorado, dubbed the Renewable Battery Connect program. Itron will integrate its IntelliFLEX platform with Tesla’s Powerwall management system, and the partners plan to increase the number of batteries that can be used during times of peak demand, as managed by Xcel.
The IntelliFLEX Aggregator Distributed Energy Resource Management System (DERMS) is designed to let energy providers localize the management of distributed batteries, utilizing a combination of residential battery storage, solar energy, electric vehicle (EV) chargers and other management systems to help balance grid energy more efficiently.
“Our Renewable Battery Connect program creates a new VPP in Colorado and we’re proud to work with Itron and Tesla, who have proven to be trusted industry partners and align with our goals to strengthen the energy grid while maintaining reliability and advancing renewable energy,” said Emmett Romine, Xcel’s VP of Customer Energy and Transportation Solutions. “This collaboration will deliver renewable, solar energy when our customers need it most.”
Truly one of the most underrated benefits of having a Tesla Powerwall.🏡🔋
Because fluctuating electricity prices suck.pic.twitter.com/GwIvOB3F1y
— TESLARATI (@Teslarati) February 27, 2025
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Itron also says the IntelliFLEX system currently helps facilitate around three million distributed energy resource devices for 30 different utilities across the U.S. The company also says the tool will give Xcel more power to manage customers’ residential batteries to help stabilize local grids.
“Integrating our IntelliFLEX solution with Tesla Powerwall demonstrates a shared vision with a leading technology partner who is at the forefront of creating electrification solutions,” said Don Reeves, SVP of Outcomes at Itron. “Through this collaboration, we are excited to bring new capabilities to Xcel Energy as they embark on its energy transition journey.”
Tesla’s Powerwall home batteries have been utilized in markets around the world, effectively letting owners store and sell stored energy back to the electrical grid in times of peak demand, outages, and other peak use cases. This kind of distributed battery system is being piloted or run in a number of U.S. states, including California, Texas, and Massachusetts, and in a few other countries and territories.
The company currently builds Powerwalls at its Gigafactory in Nevada, and the facility in November celebrated building over 1,000 of the home batteries in a single day as it continues to ramp production. In October, Tesla also said that it had over 100,000 Powerwalls participating in its VPP programs worldwide.
Tesla shows off solar, Powerwall-backed display at Giga Berlin
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Tesla quietly added this extra Sentry Mode feature to deter vandals
Tesla’s Sentry Mode gets another feature, set to add an extra layer of security against vandalism.

Amidst increased vandalism events against Tesla’s vehicles in recent weeks, the company’s Sentry Mode has increasingly been in the spotlight as a deterrent for criminal activity. As part of an update to its website this week, Tesla has also revealed a subtle addition to the recording system that should help deter vandals caught in the act.
Tesla’s Sentry Mode on Cybertrucks will soon play music at the maximum volume when the vehicle’s cameras detect activity, as detailed on the company’s redesigned Cybertruck web page this week and initially spotted by Not a Tesla App. The detail was quietly added to the Cybertruck web page, as part of the larger Sentry Mode suite of features that lets owners check out the external cameras on their electric vehicles (EVs) even when away.
“Enable Sentry Mode to monitor your unattended vehicle or trailer, and automatically activate the alarm, increase the touchscreen brightness and play music at max volume if a threat is detected,” Tesla writes on the Cybertruck page.
The music feature could use the Cybertruck’s superhorn and external speaker to play the music outside the vehicle for an even louder response to potential threats, though it’s not clear at this point whether the added feature will utilize the external or internal speakers. The music feature is also not detailed on Tesla’s web pages for other vehicles at this point, though it would be surprising to see it only available on the Cybertruck given that Sentry Mode is available across the company’s entire lineup.
You can also see the Sentry Mode image that appears on the touchscreen when activated below.

Credit: Tesla
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Tesla details the features from Sentry Mode in its owner’s manuals as follows:
When enabled, your vehicle’s cameras remain powered on and ready to record suspicious activity around your vehicle when Cybertruck is locked and in Park. Think of Sentry Mode as an intelligent vehicle security system that alerts you when it detects possible threats nearby.
If a threat is detected or the vehicle sensors determine there is a lot of jerky movement like when getting towed or shaken, Sentry Mode:
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- Pulses the headlights.
- Sounds the alarm.
- Displays a message on the touchscreen that indicates cameras may be recording to inform individuals outside of the vehicles.
- Alerts you of the alarm on the mobile app.
- Saves footage of the event to a USB drive (if installed)
Earlier this week, CEO Elon Musk also said that Tesla was increasing security at the company’s stores, along with activating Sentry Mode on all vehicles at the company’s locations. Musk also said earlier this month that it could make its vehicles automatically honk at people who come near or touch the vehicle, which would take a similar approach to scaring off people potentially keying or otherwise vandalizing a Tesla.
Tesla has ramped up security and activated Sentry Mode on all vehicles at stores https://t.co/3HwUgE8ZoF
— Elon Musk (@elonmusk) March 20, 2025
Following a substantial uptick in protests and vandalism targeting Tesla’s vehicles in response to Musk’s recent actions at Trump’s inauguration and since with the newly created government efficiency, the Federal Bureau of Investigation (FBI) has begun looking into several of these incidents.
Additionally, President Donald Trump said that Tesla attacks would be categorized as “domestic terrorism,” even suggesting that some of those who have been recently arrested in these cases could be sent to prison camps in El Salvador, where the administration has recently been sending migrants.
“I look forward to watching the sick terrorist thugs get 20 year jail sentences for what they are doing to Elon Musk and Tesla,” Trump wrote in a post on his social media platform Truth Social. “Perhaps they could serve them in the prisons of El Salvador, which have become so recently famous for such lovely conditions!”
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