It appears that Tesla’s rear casting and structure improvements for the Model Y have been designed to improve the safety of passengers who will occupy the vehicle’s future third row of seats.
As Sandy Munro continues to dive into the company’s new all-electric crossover, several clues hint toward the vehicle’s improved rear safety design. Munro mentions multiple design improvements that range from thicker longitudinal bars to prevent crunching in the even of an accident, to new bolt shapes that decrease weight and improve durability.
Munro first looks at the castings on the side rails of the Model Y. The attachment points on each side of the car indicate they are one piece and are not welded on. “They’re plenty strong, and you can see they’re just cast in place,” he said. Also, the under-seat points are 3 to 3.5mm thick. Munro suggests Tesla moved added density to other areas that may be more susceptible to being compromised in an accident. “There is a lot of good stuff here. I like that.”
According to Munro, Model Y has improved fixture points on the rear longitudinals that run from the front to the back of the car. While the two bolts on the front of the longitudinals are standard, the top bolt on the rear end is scooped out. “These are common on Japanese cars. See how it’s dished out? The Japanese use this for weight reduction, but it is also good for a shear bolt. So my guess is this may be something to do with crashworthiness,” Munro said.
Shear bolts are commonly used to protect equipment from sudden impact or excessive load. They are often referred to as “anti-theft bolts” and popular among assemblies that may be subjected to occurrences of excessive force. However, they are ideal for safety and an accident would maintain the structural integrity of the rear portion of the car, keeping those seated in the back safe from injury during a violent collision.
Speculation from the Detroit veteran suggests the Model Y’s third row of seats will be rear-facing, especially as the design of the mounting brackets only leads Munro to believe that the sixth and seventh passengers will be looking out of the vehicle’s rear windshield.
“We can’t see anything that says that we’re going to be putting front-facing seats. But, we sure can see where it could be a potential there for rear-facing seats,” Munro said.
A video Munro posted on April 4 to the company YouTube channel examined the Model Y’s potential for rear-facing third-row seats. Munro hopped into the trunk of the crossover and was impressed by the size and spaciousness, and mentioned that it was “semi-comfortable” and may be best for children based on its storage design.
Based on what is known about Tesla’s previous and upcoming third-row seating options, the design would likely be rear-facing. Jump seats in the Model S were popular among the sedan’s owners before the release of the Model X. Additionally, the upcoming release of the Plaid Mode Model S will include rear-facing jump seats that will support larger passengers instead of just children.
The Model Y was always aimed toward being the safest midsize SUV on the road. With the inclusion of an optional third row of seats, the Model Y’s rear collision safety had to be revamped and rejuvenated. The addition of shear bolts for durability and increased thickness in some areas for added strength was likely added to improve the safety of third-row passengers in an accident.
Watch Munro’s video of the improved rear castings and safety design of the Model Y below.
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
