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Tesla takes a step towards the Model Y’s single-piece cast with 410-ton machine purchase

Credit: Tesla

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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. 

The IDRA OL6100 CS, dubbed as the “Giga Press.” (Credit: IDRA)

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. 

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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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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Tesla to launch in India in July with vehicles already arriving: report

Tesla is finally making serious moves toward launching in India, with showrooms opening in July, a report claims.

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Credit: Tesla

Tesla is finally bringing its business to India, a new report indicates, as the company is already shipping vehicles from China to the market where it has attempted to launch business for several years.

We first heard of Tesla planning to launch in India about a decade ago when CEO Elon Musk and Indian Prime Minister Narendra Modi met in California at the Fremont Factory in 2015.

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Over the years, the two have hinted that the automaker would eventually land in India, but issues with import duties have delayed Tesla’s attempts.

Now, there seems to be some serious movement in Tesla’s plans, as it has reportedly shipped the first batch of vehicles from China to India, according to Bloomberg. The outlet says these are Model Y Rear-Wheel-Drive configurations.

Tesla is also planning for other parts of the launch, like preparing for Supercharging, aftermarket parts and merchandise purchasing for vehicle owners and fans, and spare parts from various regions, including the United States, China, and the Netherlands.

The company and the Indian government must have come to some sort of agreement that was catalyzed by Musk and Modi’s meeting in February in the U.S.

It is a long time coming, and it now gives Tesla access to an incredibly vast market in India, where a very small percentage of 2024’s total automotive sales were comprised of electric vehicles.

Another interesting tidbit about the launch is that the vehicles will be coming from Gigafactory Shanghai and not Gigafactory Berlin as previously thought. Reports from other publications, like Reuters, indicated the German production facility was building vehicles for India early last year.

India has a very strict policy that favors domestic manufacturing, which is why the import duties were so high for foreign automakers looking to bring their product into the market. These duties were reduced from 110 percent to just 15 percent, as long as companies aim to invest in India and meet certain investment and sales targets.

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SpaceX and Elon Musk share insights on Starship Ship 36’s RUD

Starship Ship 36 experienced a Rapid Unscheduled Disassembly during a static fire attempt.

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Elon Musk and SpaceX provided an explanation for the Rapid Unscheduled Disassembly (RUD) of Starship Ship 36 on Wednesday. As per Musk, preliminary data suggests that a nitrogen composite overwrapped pressure vessel (COPV) in the vehicle’s payload bay failed below its proof pressure.

On Wednesday evening, Ship 36 experienced a RUD during a static fire attempt. Videos of the incident that were shared online showed Starship Ship 36 exploding into a massive fireball at its launchpad in Starbase, Texas. Images taken in the aftermath of the explosion showed significant damage to the plumbing in the area. The site’s pad structure was also destroyed.

Elon Musk shared some information immediately after the incident. In a response to a post from space enthusiast @Erdayastronaut, Musk stated that “Preliminary data suggests that a nitrogen COPV in the payload bay failed below its proof pressure.”

Musk also noted that, “If further investigation confirms that this is what happened, it is the first time ever for this design.”

SpaceX provided more insight into the incident in a post on its official website.

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“After completing a single-engine static fire earlier this week, the vehicle was in the process of loading cryogenic propellant for a six-engine static fire when a sudden energetic event resulted in the complete loss of Starship and damage to the immediate area surrounding the stand.

“The explosion ignited several fires at the test site, which remains clear of personnel and will be assessed once it has been determined to be safe to approach. Individuals should not attempt to approach the area while safing operations continue,” SpaceX wrote in its post.

SpaceX highlighted that despite Starship Ship 36’s RUD, the incident will not result in any hazards to the surrounding communities in the Rio Grande Valley. And in a post on X, SpaceX also confirmed that everyone in the Starship team was safe and accounted for after Ship 36’s explosion.

While Ship 36’s RUD is a speed bump for the Starship program, SpaceX is a company that is known to grow stronger with every adversity. Thus, it would not be surprising if SpaceX implemented numerous improvements to Starship after this incident–improvements that would make the vehicle more reliable and safer than before.

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Tesla has started rolling out initial round of Robotaxi invites

Tesla is putting safety above all in its initial Robotaxi rollout.

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Credit: @BLKMDL3/X

Tesla has started rolling out an initial round of invites for its upcoming Robotaxi service in Austin, Texas.

Screenshots shared by several Tesla community members who received the invites provided a quick overview of the autonomous ride-hailing service.

As noted in a techAU report, the initial round of Robotaxi service invites has gone to longtime Tesla owners and active members of the EV community. These include owners such as @SawyerMerritt, @BLKMDL3, @WholeMarsBlog, @ItsKimJava, and @HerbertOng, all of whom shared screenshots of the invitation that Tesla has sent about the upcoming service.

You’re Invited to Early Access of Tesla Robotaxi!

The Future is Now! You’re invited to Early Access of Tesla’s Robotaxi service in Austin, TX!

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As an Early Access rider, you can be among the first to use our new Robotaxi App and experience an autonomous ride within our geofenced area in Austin. Through this exclusive preview, you’ll have the opportunity to provide valuable feedback on our Robotaxi service.

Based on Tesla’s message, it appears that participation in the service would be strictly invite-only for now. Participants must also download Tesla’s dedicated Robotaxi App to hail a ride. Rides can also be requested and initiated to and from any location within a geofenced area of Austin.

The robotaxi service will be available from 6:00 AM to 12:00 AM, seven days a week, though these hours may change depending on factors such as inclement weather. Interestingly enough, Tesla is inviting the first participants of the Robotaxi program to share photos and videos of their experience with the service.

While the vehicles themselves are autonomous and would operate without human input, the Robotaxis would still be accompanied by a Tesla staff member to monitor the vehicle. This strategy suggests that Tesla is really putting safety above all in its initial Robotaxi rollout.

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