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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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5 years ago

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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 and Arevon team up on 172-Megapack solar plus project

One of Tesla’s largest Megapack sites, the Arevon Eland solar project is supported by an impressive 1.2GWh of Megapacks.

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13 hours ago

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March 17, 2025

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Tesla Megapack
Credit: Tesla

Tesla and partner Arevon have completed the second phase of an energy storage site in Southern California, as highlighted in a short video shared this week.

On Monday, Tesla’s Megapack account on X posted a brief video on the Kern County, California “Eland” storage site, which was recently expanded to offer 300MW/1.2GWh of Megapacks supporting 758MW of solar. The so-called “Eland Solar-plus-Storage Project” site now features 172 Megapack units and 1.36 million solar panels, which the companies have previously said is roughly enough to power 200,000 homes annually.

In the video, Tesla also notes that the facility has site-level controls to regulate power output, “providing a firm resource to the grid,” and supporting the Los Angeles climate goal of reaching 100-percent renewable electricity by 2035. You can check out the clip below.

READ MORE ON TESLA MEGAPACKS: Tesla Megapack project in California housed in former steam plant

Arevon announced the official start of operations for Eland 1 in December with 150MW/600 MWh, and the Eland 2 phase has effectively doubled this. The company also appears to be on track for its targeted opening of Eland 2 in Q1 this year, though it’s not clear at the time of writing if Arevon has yet announced a start of operations for the second phase.

Last February, Arevon announced that it secured a $1.1 billion financial commitment for the remaining parts of the Eland 2 Solar-plus-Storage project, together with Eland 1 becoming one of the largest solar-plus-storage installations in the U.S. The projects also include a long-term purchase agreement from the Southern California Public Power Authority, which plans to facilitate contracts for the LA Department of Water and Power and Glendale Water and Power.

Tesla’s grid-scale Megapack batteries can store and deploy generated energy to the electrical grid, especially during periods of peak power usage, high demand, or outages. Coupled with solar or other energy sources in these kinds of solar-plus-storage sites, Tesla’s Megapacks can help support renewable energy for long periods of time, or at least add stability to the grid.

Over the past couple of years, Tesla has been deploying large-scale Megapack projects in markets around the world, as backed by an initial production facility in Lathrop, California. This “Megafactory” aims to eventually produce 10,000 Megapack units, or 40 GWh, per year, and it has been ramping up production since late 2022.

In November, the Lathrop Megafactory officially produced its 10,000th Megapack, and Tesla also started production at a second Megapack plant in Shanghai, China last month, after starting construction on the site last May. The Shanghai Megafactory is also expected to have a volume annual production of 10,000 units per year.

Additionally, Tesla has teased plans for a third Megafactory, though it has yet to disclose where such a facility would be built.

Tesla’s massive Megapack site near Melbourne is almost ready

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Tesla reveals Cybercab battery pack and range efficiency

Tesla aims to make the Cybercab the most efficient EV available, as executives revealed in an interview this week.

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15 hours ago

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March 17, 2025

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Two of the top Tesla executives recently spoke about the Cybercab in an interview with a longtime manufacturing industry expert, sharing details about the electric vehicle’s (EV’s) battery pack size, range, and more.

On Monday, Tesla’s VP of Vehicle Engineering Lars Moravy and Senior Design Executive Franz von Holzhausen told manufacturing industry veteran Sandy Munro that Tesla is targeting a battery pack of under 50kWh for the Cybercab, with “close to” 300 miles of real-world range. This would make the two-seater more efficient than any other EV currently in production, partially due to the two-seater’s highly-aerodynamic design.

Munro says he was expecting a battery pack ranging from 55kWh to 60 kWh, noting how much smaller Tesla is aiming to go. Before revealing the range targets, Moravy also detailed how the Cybercab’s aero wheel covers offer optimal aerodynamics to contribute to the impressive efficiency level.

“As much as Franz hates door handles, I hate the wheel-tire interaction, and this is really the best way for us to get the most aerodynamic wheel-tire we could get,” Moravy explains.

From the wheel covers to the overall design, however, von Holzhausen explains how much thought has gone into making the vehicle so efficient—even down to its shape.

“This car is actually really unique in terms of its teardrop shape,” von Holzhausen said. “It’s actually quite narrow in the rear compared to the front. Obviously, you covered the discs, but the aero efficiency is a huge factor in getting to higher range with a smaller battery pack.”

The fact that the vehicle only has two seats also contributes to some of the design choices Tesla was able to implement, as the executive continues to explain.

“Really, because it’s a two-seater we were able to really narrow the hips on this car, and when you come to the rear, you actually start to see how narrow it is, but it’s not unattractive,” he adds.

Credit: Tesla | X

READ MORE ON TESLA CYBERCAB: Tesla reveals design inspiration behind Cybercab’s gold color

Moravy reiterates that Tesla is already starting to install production equipment for the Cybercab at Gigafactory Texas, which was revealed in a shareholder’s letter in late January. He also echoes plans that Tesla is aiming for prototype builds for the Cybercab by this summer, along with a launch event around early 2026.

In recent weeks, increasing numbers of Cybercabs have also been seen testing at Giga Texas, and longtime drone pilot and factory observer Joe Tegtmeyer said that he saw as many as six driving around the site on Monday.

Last month, Moravy also alluded to plans to make the Cybercab “road-trip-capable,” going long distances with wireless charging along the way to make it completely autonomous for passengers.

Along with talking about the Cybercab’s super-efficient design, the two executives also reiterate discussions about the art deco-inspired design of the robotaxi and the larger Robovan, both of which were unveiled in an event in October. Munro and the executives also go on to sit inside the Robovan while talking a bit about its design.

You can see footage from Teslarati‘s first full ride in the Cybercab below, as captured at the “We, Robot” event in Southern California. Or, check out the full Cybercab and Robovan episode from Munro, Moravy, and von Holzhausen below that, clocking in at just under 25 minutes.

Tesla says its Cybercab wireless charging efficiency is ‘well above 90%’

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SpaceX rescue mission for stranded ISS astronauts nears end — Here’s when they’ll return home

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16 hours ago

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March 17, 2025

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Credit: SpaceX

SpaceX is ready to bring home Butch Wilmore and Suni Williams, the two astronauts that have been stranded on the International Space Station (ISS) for nine months.

Last week, SpaceX launched its Crew-10 mission, which would dock onto the ISS late Saturday night and be the two astronauts’ ride home. Now, the end is in sight, and it appears both NASA and SpaceX are planning to have the two home this week, perhaps earlier than expected.

SpaceX readies to rescue astronauts from International Space Station

The agency and the company have announced that Dragon will autonomously undock from the ISS on Tuesday at 1:05 a.m. ET and should re-enter Earth’s atmosphere and splashdown off the Florida coast about 17 hours later.

SpaceX said:

“SpaceX and NASA are targeting Tuesday, March 18 at 1:05 a.m. ET for Dragon to autonomously undock from the International Space Station. After performing a series of departure burns to move away from the space station, Dragon will conduct multiple orbit-lowering maneuvers, jettison the trunk, and re-enter Earth’s atmosphere for splashdown off the coast of Florida approximately 17 hours later the same day.”

Crew-9 astronaut Nick Hague will be alongside Williams and Wilmore on the flight home, along with Roscosmos cosmonaut Aleksandr Gorbunov. Hague and Gorbunov have been in space since Saturday, September 28.

SpaceX was tasked with bringing Wilmore and Williams home after the Boeing Starliner that sent them there was determined not to be suitable for their return.

A report from the New York Post in late August said that Boeing employees routinely made fun of SpaceX workers, only for the company to bail them out:

SpaceX bails out Boeing and employees are reportedly ‘humiliated’

Crew-10 will bring the astronauts home, ending an extensive and unscheduled stay in space.

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