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Tesla takes a step towards the Model Y’s single-piece cast with 410-ton machine purchase
When Elon Musk was interviewed in an episode of the Third Row Podcast earlier this year, he noted that the Model Y crossover’s rear underbody would eventually be built with a single-piece casting. This is quite a bold target, and one that can make the Model Y into one of the most cost-effective vehicles on the market today, electric or otherwise.
“The current version of Model Y has basically two big high-pressure diecast [HPDC] aluminum castings that are joined and there’s still a bunch of other bits that are attached. Later this year. We’ll transition to the rear underbody being a single-piece casting that also integrates the rear crash rails,” Musk remarked.
There are many advantages to using a single-piece cast for the Model Y. The vehicle could be built in a relatively simple manner by using fewer parts, helping the company optimize its production costs. Developing such a design only takes a lot of time and effort, as indicated by Elon Musk in the podcast.
“It gets better. The current castings, because you’ve got to interface with so many different things, we have to CNC-machine the interfaces and there’s a bunch of things that have to be joined; they have datums on them and that kind of thing. The single-piece casting has no CNC machining – it doesn’t even have datums. It took us a lot of iterations, by the way, to get there,” the CEO added.
It appears that Tesla is now at a point where it is ready to pursue the Model Y’s single-piece cast. As indicated in a recent report on SAE Automotive Engineering, Tesla has purchased a machine from the IDRA Group, an Italian firm that makes HPDC equipment. What is rather interesting is that the machine that Tesla purchased is a gargantuan piece of equipment capable of producing the Model Y’s special components.
The machine that Tesla purchased, called the IDRA OL6100 CS, features an upgraded locking force that’s specially designed for the Model Y’s castings. Interestingly enough, the OL6100 CS is fondly dubbed as the “Giga Press” due to its size and power. The machine is 64 feet long and 17 feet high, and it weighs a whopping 410 tons. That’s roughly as heavy as five Space Shuttles.
Laurie Harbour, president at Harbour Results Inc., a manufacturing consultancy firm, noted that the new machine could effectively optimize the Model Y’s production process. With the Giga Press in use, Harbour estimates that Tesla could save about 20% on labor cost.
“Even with a big cycle time, you eliminate all the labor to assemble pieces and subcomponents. You’re saving on automation cells, you’re saving on people. It would be tough to put dollars to it, but think of multiple suppliers doing stampings, you could save maybe 20% on labor cost. And reduction in footprint is major. My guess is that it’s a net-net efficiency gain,” she said.
What is particularly interesting is that the Model Y was already highly optimized to begin with. Unlike the early production Model 3, which featured over 70 pieces in its rear underbody, early production Model Ys only had two large casts at the rear. This was confirmed by automotive teardown expert Sandy Munro, who conducted a thorough teardown of the Tesla Model Y from top to bottom.
Reflecting on the Model Y’s current casts, Munro noted that the vehicle had “two of the biggest castings we’ve ever seen in a car,” especially one in a consumer vehicle the size of the all-electric crossover. The teardown expert stated that other companies, such as BMW and Audi, have all used castings, but nothing comes close to the one that Tesla currently uses in the Model Y. And once Tesla moves to a single-piece casting system for the vehicle, Munro noted that the American electric car maker could “win the price.”
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Tesla hints toward Premium Robotaxi offering with Model S testing
Why Tesla has chosen to use a couple of Model S units must have a reason; the company is calculated in its engineering and data collection efforts, so this is definitely more than “we just felt like giving our drivers a change of scenery.”
Tesla Model S vehicles were spotted performing validation testing with LiDAR rigs in California today, a pretty big switch-up compared to what we are used to seeing on the roads.
Tesla utilizes the Model Y crossover for its Robotaxi fleet. It is adequately sized, the most popular vehicle in its lineup, and is suitable for a wide variety of applications. It provides enough luxury for a single rider, but enough room for several passengers, if needed.
However, the testing has seemingly expanded to one of Tesla’s premium flagship offerings, as the Model S was spotted with the validation equipment that is seen entirely with Model Y vehicles. We have written several articles on Robotaxi testing mules being spotted across the United States, but this is a first:
🚨 Tesla is using Model S vehicles fitted with LiDAR rigs to validate FSD and Robotaxi, differing from the Model Ys that it uses typically
Those Model Y vehicles have been on the East Coast for some time. These Model S cars were spotted in California https://t.co/CN9Bw5Wma8 pic.twitter.com/UE55hx5mdd
— TESLARATI (@Teslarati) December 11, 2025
Why Tesla has chosen to use a couple of Model S units must have a reason; the company is calculated in its engineering and data collection efforts, so this is definitely more than “we just felt like giving our drivers a change of scenery.”
It seems to hint that Tesla could add a premium, more luxury offering to its Robotaxi platform eventually. Think about it: Uber has Uber Black, Lyft has Lyft Black. These vehicles and services are associated with a more premium cost as they combine luxury models with more catered transportation options.
Tesla could be testing the waters here, and it could be thinking of adding the Model S to its fleet of ride-hailing vehicles.
Reluctant to remove the Model S from its production plans completely despite its low volume contributions to the overall mission of transitioning the world to sustainable energy, the flagship sedan has always meant something. CEO Elon Musk referred to it, along with its sibling Model X, as continuing on production lines due to “sentimental reasons.”
However, its purpose might have been expanded to justify keeping it around, and why not? It is a cozy, premium offering, and it would be great for those who want a little more luxury and are willing to pay a few extra dollars.
Of course, none of this is even close to confirmed. However, it is reasonable to speculate that the Model S could be a potential addition to the Robotaxi fleet. It’s capable of all the same things the Model Y is, but with more luxuriousness, and it could be the perfect addition to the futuristic fleet.
News
Rivian unveils self-driving chip and autonomy plans to compete with Tesla
Rivian, a mainstay in the world of electric vehicle startups, said it plans to roll out an Autonomy+ subscription and one-time purchase program, priced at $49.99 per month and $2,500 up front, respectively, for access to its self-driving suite.
Rivian unveiled its self-driving chip and autonomy plans to compete with Tesla and others at its AI and Autonomy Day on Thursday in Palo Alto, California.
Rivian, a mainstay in the world of electric vehicle startups, said it plans to roll out an Autonomy+ subscription and one-time purchase program, priced at $49.99 per month and $2,500 up front, respectively, for access to its self-driving suite.
CEO RJ Scaringe said it will learn and become more confident and robust as more miles are driven and it gathers more data. This is what Tesla uses through a neural network, as it uses deep learning to improve with every mile traveled.
He said:
“I couldn’t be more excited for the work our teams are driving in autonomy and AI. Our updated hardware platform, which includes our in-house 1600 sparse TOPS inference chip, will enable us to achieve dramatic progress in self-driving to ultimately deliver on our goal of delivering L4. This represents an inflection point for the ownership experience – ultimately being able to give customers their time back when in the car.”
At first, Rivian plans to offer the service to personally-owned vehicles, and not operate as a ride-hailing service. However, ride-sharing is in the plans for the future, he said:
“While our initial focus will be on personally owned vehicles, which today represent a vast majority of the miles to the United States, this also enables us to pursue opportunities in the rideshare space.”
The Hardware
Rivian is not using a vision-only approach as Tesla does, and instead will rely on 11 cameras, five radar sensors, and a single LiDAR that will face forward.
It is also developing a chip in-house, which will be manufactured by TSMC, a supplier of Tesla’s as well. The chip will be known as RAP1 and will be about 50 times as powerful as the chip that is currently in Rivian vehicles. It will also do more than 800 trillion calculations every second.
Meet the Rivian Autonomy Processor.
Fast, smart, scalable and purpose-built for autonomous driving and the world of physical AI. Hitting the open road in 2026. pic.twitter.com/0wYXi5WKy7
— Rivian (@Rivian) December 11, 2025
RAP1 powers the Autonomy Compute Module 3, known as ACM3, which is Rivian’s third-generation autonomy computer.
ACM3 specs include:
- 1600 sparse INT8 TOPS (Trillion Operations Per Second).
- The processing power of 5 billion pixels per second.
- RAP1 features RivLink, a low-latency interconnect technology allowing chips to be connected to multiply processing power, making it inherently extensible.
- RAP1 is enabled by an in-house developed AI compiler and platform software
As far as LiDAR, Rivian plans to use it in forthcoming R2 cars to enable SAE Level 4 automated driving, which would allow people to sit in the back and, according to the agency’s ratings, “will not require you to take over driving.”
More Details
Rivian said it will also roll out advancements to the second-generation R1 vehicles in the near term with the addition of UHF, or Universal Hands-Free, which will be available on over 3.5 million miles of roadway in the U.S. and Canada.
More than any other feature, our owners have asked for more hands-free miles.
With Universal Hands-Free, you can now enjoy hands-free assisted driving on any road with clearly defined lanes. That’s roughly 3.5 million miles in the U.S. and Canada.
Look for it in our next… pic.twitter.com/ZFhwVzvt6b
— Rivian (@Rivian) December 11, 2025
Rivian will now join the competitive ranks with Tesla, Waymo, Zoox, and others, who are all in the race for autonomy.
News
Tesla partners with Lemonade for new insurance program
Tesla recently was offered “almost free” coverage for Full Self-Driving by Lemonade’s Shai Wininger, President and Co-founder, who said it would be “happy to explore insuring Tesla FSD miles for (almost) free.”
Tesla owners in California, Oregon, and Arizona can now use Lemonade Insurance, the firm that recently said it could cover Full Self-Driving miles for “almost free.”
Lemonade, which offered the new service through its app, has three distinct advantages, it says:
- Direct Connection for no telematics device needed
- Better customer service
- Smarter pricing
The company is known for offering unique, fee-based insurance rates through AI, and instead of keeping unclaimed premiums, it offers coverage through a flat free upfront. The leftover funds are donated to charities by its policyholders.
On Thursday, it announced that cars in three states would be able to be connected directly to the car through its smartphone app, enabling easier access to insurance factors through telematics:
Lemonade customers who own @Tesla vehicles in California, Oregon, and Arizona can now connect their cars directly to the Lemonade app! ⚡🚘
Direct connection = no telematics device needed 📵
Better customer experience 💃
Smarter pricing with Lemonade 🧠This is a game-changer… pic.twitter.com/jbabxZWT4t
— Lemonade (@Lemonade_Inc) December 11, 2025
Tesla recently was offered “almost free” coverage for Full Self-Driving by Lemonade’s Shai Wininger, President and Co-founder, who said it would be “happy to explore insuring Tesla FSD miles for (almost) free.”
The strategy would be one of the most unique, as it would provide Tesla drivers with stable, accurate, and consistent insurance rates, while also incentivizing owners to utilize Full Self-Driving for their travel miles.
Tesla Full Self-Driving gets an offer to be insured for ‘almost free’
This would make FSD more cost-effective for owners and contribute to the company’s data collection efforts.
Data also backs Tesla Full Self-Driving’s advantages as a safety net for drivers. Recent figures indicate it was nine times less likely to be in an accident compared to the national average, registering an accident every 6.36 million miles. The NHTSA says a crash occurs approximately every 702,000 miles.
Tesla also offers its own in-house insurance program, which is currently offered in twelve states so far. The company is attempting to enter more areas of the U.S., with recent filings indicating the company wants to enter Florida and offer insurance to drivers in that state.
Tesla hints toward Premium Robotaxi offering with Model S testing
Rivian unveils self-driving chip and autonomy plans to compete with Tesla
