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The Model Y is an understated Trojan Horse for Tesla’s manufacturing ambitions
The launch of the Tesla Model Y is, in several ways, an understated and undramatic event. There were no surprise vehicles at the end of the crossover’s presentation, nor were there any announcements about the number of pre-orders the electric car maker received for the seven-seater. Tesla has been pretty quiet about the Model Y since, too, as updates on the crossover have mostly come through insider reports and patent applications from the company.
It is through these patent applications that one could see the potential of the Model Y to revolutionize Tesla’s overall manufacturing operations. A look at two patents that are tailor-fit for the Model Y, for example, suggests that Tesla will be adopting a far more innovative production process for the vehicle compared to its past electric cars, including the mass-market Model 3 sedan, a vehicle that is essentially carrying Tesla into its current transition into a mainstream car manufacturer. With this in mind, the Model Y could even be described as a Trojan Horse of sorts, carrying the electric car maker’s innovations (mostly) under the radar.
One of these innovations is a rigid wiring system that will allow Tesla to drastically reduce the wiring of the Model Y compared to its older stablemates. Using the company’s design outlined in its patent, Tesla is expected to use only around 100 meters of wiring for the Model Y, far less than the 1.5 km of cabling used in the Model 3. Such a design also aids the company’s automation initiatives, as the rigid wiring harness will be easier to install by the company’s robots.
Another, even more notable innovation lies in a patent for a “Multi-Directional Unibody Casting Machine for a Vehicle Frame and Associated Methods” that seems to have been teased by company executives in the past. Elon Musk has mentioned that the company’s new casting machine will have the capability to cast pretty much the entire body of a vehicle in one piece, essentially eliminating the need for numerous welds across the body. “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,” Musk said.
These new innovations outlined in Tesla’s patent applications hint at the Model Y being the company’s first vehicle to adopt such designs in its wiring and casting. This is great news for the company’s upcoming vehicles like the Tesla Pickup Truck, the Semi, and the next-generation Roadster, all of which will likely benefit from these optimizations. More importantly, this is also great news for the Model 3.
Tesla’s struggles with the Model 3 ramp in the United States have been well-documented, as the company had to abandon a widely-automated approach to producing the vehicle to one that was more balanced between humans and machines. With the Model Y, Tesla could essentially start anew and experiment with more ambitious and manufacturing models once more. Fortunately for the Model 3, the vehicle shares about 75% of its parts with the Model Y, which means that production improvements that work for the crossover would likely be applicable for the midsize sedan as well.
The Tesla Model Y’s manufacturing revolution might begin sooner than expected, especially with the start of production at the company’s Gigafactory 3 site in Shanghai. Gigafactory 3 is designed to produce affordable versions of the Model 3 and Model Y for the Chinese market, suggesting that the facility will be optimized for speed and volume. It would then be interesting to see how Tesla produces the Model 3 (and later, the Model Y) on the site, as it could provide a glimpse at how much the company has improved based on lessons learned from the electric sedan’s ramp in the United States.
H/T Long Term Tips.
The Tesla Model X has always been one of the company’s most loved vehicles, despite its low sales figures, which can be attributed to its high price tag.
However, the Model X has been a signature item on Tesla’s menu of cars, most notably recognized by its Falcon Wing Doors, which are aware of its surroundings and open according to what’s around it.
But recent improvements to the Model X were looking slim to none, but it appears most of the fixes actually happened under the body, at least according to Tesla’s Vice President of Powertrain, Lars Moravy.
In a recent interview with Car and Driver, Moravy detailed all of the changes to the 2026 iteration of the vehicle, which was about 400 pounds lighter than it was originally. The biggest change is a modification with the rear motor, switching from an induction-type motor to a permanent-magnet design and optimizing the half-shafts, which shed about 100 pounds.
Tesla also got “almost 80 pounds out of the interior bits and pieces,” which “included making parts thinner, different manufacturing process choices, and incorporating airbag-deployment requirements into the headliner fabric,” the report said.
Additionally, the standard five-passenger, bench seat configuration saved 50 pounds by ditching pedestal mounting. This also helped with practicality, as it helped the seat fold flat. Engineers at Tesla also saved 44 pounds from the high-voltage wiring through optimizing the wiring from the charge-port DC/DC converter and switching from copper to aluminum wiring.
Tesla makes a decision on the future of its flagship Model S and Model X
Tesla also simplified the cooling system by reducing the number of radiators. It also incorporated Nürburgring cooling requirements for the Plaid variant, which saved nearly 30 pounds.
Many Tesla fans will be familiar with the megacastings, manufactured in-house by presses from IDRA, which also saves more than 20 pounds and boosts torsional stiffness by around 10 percent. Tweaks to the suspension also saved 10 pounds.
People were truly disappointed with what Tesla did with the Model S and Model X, arguing that the cars needed a more severe exterior overhaul, which might be true. However, Tesla really did a lot to reduce the weight of the vehicle, which helps increase range and efficiency. According to Grok, every 200 pounds removed adds between 7 and 15 percent to range estimations.
This makes sense considering the range estimations both increased by 7 percent from the Model X’s 2025 configuration to the 2026 builds. Range increased on the All-Wheel-Drive trim from 329 miles to 352 miles, while the Plaid went from 314 miles to 335 miles.
Tesla has officially launched its first branded Supercharger just months after initiating a new program that allows third-party companies to brand their own charging piles.
The site opened in Land O’ Lakes, Florida, and features eight V4 Supercharging stalls offering up to 325 kW of charging speed. It appears it was purchased by a company called Suncoast Credit Union. This particular branch is located Northeast of Tampa, which is on the Gulf of Mexico.
It features graphics of Florida animals, like alligators:
Here’s a video of the graphics being installed on the Tesla Superchargers at this site: https://t.co/oIfEPNZjAH pic.twitter.com/ENWakZ2qT9
— TESLARATI (@Teslarati) November 20, 2025
Tesla launched this program back in September, and it basically was a way to expand its Supercharger presence and also allow companies to pay for the infrastructure. Tesla maintains it. When it announced the “Supercharger for Business,” it said:
“Purchase and install Superchargers at your business. Superchargers are compatible with all electric vehicles, bringing EV drivers to your business by offering convenient, reliable charging.”
The program does a few things. Initially, it expands EV charging infrastructure and makes charging solutions more readily available for drivers. It can also attract people to those businesses specifically.
Tesla launches new Supercharger program that business owners will love
The chargers can also be branded with any logo that the business chooses, which makes them more personalized and also acts as an advertisement.
The best part is that the customers do not have to maintain anything about the Supercharger. Tesla still takes care of it and resolves any issues:
“We treat your site like we treat our sites. By providing you with a full-service package that includes network operations, preventative maintenance, and driver support, we’re able to guarantee 97% uptime–the highest in the industry.”
It appears the Superchargers will also appear within the in-car nav during routing, so they’ll be publicly available to anyone who needs to use them. They are still available to all EVs that have worked with Tesla to utilize its infrastructure, and they are not restricted to people who are only visiting the business.
Tesla has revealed its Cybertruck light bar installation fix after a recall exposed a serious issue with the accessory.
Tesla and the National Highway Traffic Safety Administration (NHTSA) initiated a recall of 6,197 Cybertrucks back in October to resolve an issue with the Cybertruck light bar accessory. It was an issue with the adhesive that was provided by a Romanian company called Hella Romania S.R.L.
Tesla recalls 6,197 Cybertrucks for light bar adhesive issue
The issue was with the primer quality, as the recall report from the NHTSA had stated the light bar had “inadvertently attached to the windshield using the incorrect surface primer.”
Instead of trying to adhere the light bar to the Cybertruck with an adhesive, Tesla is now going to attach it with a bracketing system, which will physically mount it to the vehicle instead of relying on adhesive strips or glue.
Tesla outlines this in its new Service Bulletin, labeled SB-25-90-001, (spotted by Not a Tesla App) where it shows the light bar will be remounted more securely:
The entire process will take a few hours, but it can be completed by the Mobile Service techs, so if you have a Cybertruck that needs a light bar adjustment, it can be done without taking the vehicle to the Service Center for repair.
However, the repair will only happen if there is no delamination or damage present; then Tesla could “retrofit the service-installed optional off-road light bar accessory with a positive mechanical attachment.”
The company said it would repair the light bar at no charge to customers. The light bar issue was one that did not result in any accidents or injuries, according to the NHTSA’s report.
This was the third recall on Cybertruck this year, as one was highlighted in March for exterior trim panels detaching during operation. Another had to do with front parking lights being too bright, which was fixed with an Over-the-Air update last month.
Tesla Model X lost 400 pounds thanks to these changes
Tesla launches its new branded Supercharger for Business with first active station
