A recent episode of Sandy Munro’s Tesla Model Y teardown series has revealed that the electric car company utilized friction stir welding (FSW) for the crossover’s thermal management system. The welding technique is commonly used among aerospace companies, like SpaceX, as a way to maintain the strength of aluminum parts while securing a reliable bond between pieces.
Munro’s analysis of the Octovalve coolant system revealed Tesla’s techniques for the revised thermal management portion of the Model Y. Munro discovered the Octovalve on April 4 after digging into the Model Y’s internal build. The new coolant assembly seemed to be a revised version of the Model 3’s “Superbottle,” which served as the heart of the sedan’s thermal management system.
A car’s thermal management apparatus is responsible for controlling and maintaining proper temperatures in critical portions of the vehicle. In the case of the Model Y, the Octovalve is responsible for motor, battery, and cabin cooling, according to Munro. The Detroit auto veteran said that typically, these systems should not be cooling the cabin if they are controlling battery or motor temperature. The thermal management system in the Model Y seems to be controlling the cabin, the battery, the electronics, and the motor nonetheless.
The Octovalve seems to be a state-of-the-art system as it uses, “some clever little ball valves that open and close to make sure that everything’s getting heated or everything’s being cooled to where it needs to be,” Munro said.
With the assembly overlooking the temperature for these many parts of the vehicle, the system is subjected to drastic and sharp temperature changes. Over time, the difference between heat and cold can begin to weaken portions of the car part, especially if it was exposed to excessive temperatures during manufacturing. This is where some SpaceX-grade solutions come into play.
Tesla chose to utilize friction stir welding for its aluminum portions of the coolant assembly. “This is a cool way of putting two parts of aluminum together, some other materials as well, but aluminum is kind of the most suited for it. And in essence, what happens is you have a stylus that spins around very very quickly. It pokes through the two pieces of metal that you want to friction stir weld. Then, it goes around the outside edge, and what it does is it uses the plastic state or thixotropic state of the aluminum to bind it together,” Munro said.
Simply put, the process allows aluminum to reach a temperature that allows two pieces of metal to come together with a strong bond, but it never turns the metal into a soft, liquid-like state. “It’s like soft butter, butter that you could see is firm, but you could cut it with a knife.”
The advantage of using this process is that the heat from the welding process only applies to the outer edges of the metal. The additional material that is not bonded to anything does not see the heat and is not weakened by the welding process. Stir welding is also time effective as it can be completed in a short period, but it is a careful process that does not apply unneeded stress upon the rest of the assembly.
SpaceX uses friction stir welding for its rockets, as it increases strength by exposing only the bonded portions of two pieces of metal to each other. Friction stir welding was used by SpaceX back in 2008 when the company was combining barrel sections of the Falcon 9’s second stage. “The FSW joins metal without flames, sparking, inert gasses, or fumes, and produces a far superior weld in aluminum-lithium alloys as compared to traditional methods,” SpaceX said in a news update.
In the spirit of humor, Tesla and Elon Musk saw the Octovalve as a perfect opportunity to not only improve the performance of the vehicle temperature regulation system but also as an appropriate time to sprinkle in some additional humor in the form of an Easter Egg. The Model 3 donned a cape-wearing bottle-figured superhero for its “Superbottle” system, while the Model Y includes a snowflake-stamped Octopus as an Easter Egg.
Tesla has increased the effectiveness of its thermal management with the introduction of the Model Y’s Octovalve system. Elon Musk stated that it was some of the best engineering he had ever seen. The welding process could increase the longevity of the machine through its lack of exposure to excessive heat and stress during manufacturing.
Watch Munro’s video on the Model Y’s Octovalve welding below.
Elon Musk
Tesla releases cryptic teaser for something massive and it’s coming this week
On Sunday morning, Tesla released a nine-second teaser video of what appears to be either a vehicle wheel, fan, or some sort of propeller, but there are no real clues as to what it could be exactly.
Tesla has released a cryptic teaser for something massive, and it will release details on it this week. With many different projects in the works, there is a lot of speculation going on about what it could potentially be, but we have a few ideas.
On Sunday morning, Tesla released a nine-second teaser video of what appears to be either a vehicle wheel, fan, or some sort of propeller, but there are no real clues as to what it could be exactly.
It then ends with “10/7,” meaning it will announce something on October 7, which is this Tuesday:
— Tesla (@Tesla) October 5, 2025
Given that Tesla has been working on a handful of pretty notable projects that are set for unveiling at the end of this year, and there are some clues that seem to point in their direction with this short teaser video.
There are two projects that come to mind almost immediately: the Tesla Roadster is one, and the “E41” or affordable model is the other. Here’s what we know about both:
Tesla Roadster Demo Event
Tesla said earlier this year that it would have a demo event for the Roadster to unveil some new technologies and show off what it has been working on over the past few years.
There have been a lot of crazy things in the works for the Roadster, including a SpaceX package that would use cold-gas thrusters for an insane 1.1-second 0-60 MPH acceleration rate. This package was also supposed to help it hover, something CEO Elon Musk has teased for the past few years.
The Roadster was ready for release earlier this year, but after Chief Designer Franz von Holzhausen and VP of Powertrain Lars Moravy showed Musk what they had come up with, he wanted more.
Moravy said on the Ride the Lightning podcast earlier this year:
“What we had come up with exceeded what we originally planned. So, Elon was like, ‘Wow, great. Let’s do more!’”
The Roadster event was coined as “the most epic demo,” and since it was planned for the end of 2025, it is totally feasible to believe this could be it.
Tesla ‘E41’ Affordable Model
Some believe the teaser could be the official launch of Tesla’s affordable model, which Musk said earlier this year is simply a stripped down Model Y.
There have been some sightings of this vehicle in the past few weeks, including one on Friday that showed the vehicle completely uncovered for the first time:
🚨 It looks like the new affordable Tesla Model Y was spotted near Giga Texas
Model Y body with the Model 3 fascia, no glass roof, and looks as if there is a front bumper camera!
Should be coming soon! https://t.co/UAXQMHjM23 pic.twitter.com/9lC5te9GnW
— TESLARATI (@Teslarati) October 3, 2025
The launch of the affordable model makes sense, especially from a timing perspective. With the $7,500 EV tax credit officially coming to a close on September 30, many are wondering how Tesla will spark growth in its deliveries. A more affordable EV would be the perfect response, and it is something that Tesla has been working on for some time.
Other Potential Ideas
There are some pretty interesting ideas as to what the teaser could be apart from the Roadster or affordable model. Some believe it could be a cooling fan for a GPU cluster, which would make sense considering Tesla’s prowess in data.
Grok also made an interesting guess, stating it could be a propeller for a secret air taxi Tesla is developing. This seems sort of our of left field.
We do know Tesla hosted a handful of influencers at Gigafactory Texas this past week, so whatever the company showed them is likely what will be unveiled on Tuesday.
News
Tesla Optimus is learning martial arts in new video teasing capabilities
For the past few months, Tesla has been refining its capabilities and making some serious progress on what Optimus is capable of. This morning, Musk released a new video showing Optimus learning Kung Fu, perhaps its most impressive feat yet.
Tesla Optimus is learning martial arts, a new video released by CEO Elon Musk shows, a crazy development and advancement in the robotics project the company has been working on for a few years.
Optimus has been a major focus of Tesla for the past several years, especially as Musk has said he believes it will be the biggest product of all time and could be the biggest contributor to the company’s valuation.
For the past few months, Tesla has been refining its capabilities and making some serious progress on what Optimus is capable of. This morning, Musk released a new video showing Optimus learning Kung Fu, perhaps its most impressive feat yet:
Tesla Optimus learning Kung Fu pic.twitter.com/ziEuiiKWn7
— Elon Musk (@elonmusk) October 4, 2025
The video shows Optimus working with a Kung Fu teacher, known as a Shifu, going through what appears to be some sort of routine of combinations. It’s quite impressive to see the fluidity of the movements and Optimus’s ability to keep up with Shifu.
Tesla has been “working hard” to scale Optimus production, Musk said last week, a project that has obviously confronted both AI and manufacturing teams with a variety of challenges.
The plan is to have an annual production run-rate of one million units by 2030, and there were plans to build 5,000 units this year.
Musk still believes Optimus will make up roughly 80 percent of Tesla’s value. In January, he said it would be “overwhelmingly the value of the company.”
Tesla plans to launch the Gen 3 version of Optimus soon, and although a video of a new-look prototype was released by Marc Benioff, the CEO of Salesforce, the company’s frontman stated that this was not what the next-generation prototype would look like.
Elon Musk confirms Tesla has never shown Optimus V3 design yet
This video seems to show there is still significant progress being made on the Optimus project, and it will be perhaps one of the most impressive humanoid robots available to consumers in the coming years.
Elon Musk
Tesla Full Self-Driving v14 gets new release date, Elon Musk details
“Last minute bug cropped up with V14. Released is pushed to Monday, but that gives us time to add a few more features.”
Tesla’s Full Self-Driving version 14 has gotten a new release date after new details from CEO Elon Musk opened up some new perspectives on the suite.
Originally slated for an “early wide release” of v14 this past week, then a launch of v14.1 and v14.2 this week and next week, respectively, delays arose after Tesla’s Autopilot team found some issues within the software.
Tesla FSD V14 set for early wide release next week: Elon Musk
Musk detailed on X this morning that a “last minute bug” appeared before release, which has now pushed FSD v14’s release back to this Monday:
Last minute bug cropped up with V14. Released is pushed to Monday, but that gives us time to add a few more features.
— Elon Musk (@elonmusk) October 4, 2025
Musk also said the delay would give Tesla the ability to “add a few more features,” which seems like an added advantage, although he did not provide any additional details on what these features could be.
In classic Musk fashion, he has teased the capabilities of this version of the FSD suite since it became public knowledge that Tesla was working on it. He said that it is the second most important update for the AI/Autopilot team since FSD v12.
V14 will have a parameter count that is ten times what previous iterations were, which should provide more accuracy and a more human-like operation.
🚨 Tesla is making “significant improvements” in FSD software and plans to increase parameter count by roughly 10x from what people are currently experiencing pic.twitter.com/r974W6ToGi
— TESLARATI (@Teslarati) July 23, 2025
Musk has said v14 “feels alive” and has used the word “sentient” to describe its performance. The goal with the new FSD rollouts is to eliminate as many interventions as possible, making it as close to human driving as possible.
Tesla releases cryptic teaser for something massive and it’s coming this week
Tesla Optimus is learning martial arts in new video teasing capabilities
Tesla Full Self-Driving v14 gets new release date, Elon Musk details
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