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.
News
Tesla extends Model Y L delivery estimates to December 2025
This suggests that the six-seat, all-electric crossover SUV has become fully sold out for both October and November.
Tesla’s new extended-wheelbase Model Y L seems to be getting a lot of traction in China. As per Tesla China’s order page, the estimated delivery date for new vehicle orders is now listed as December 2025.
This suggests that the six-seat, all-electric crossover SUV has become fully sold out for both October and November. This bodes well for the vehicle, considering that it is currently the most expensive trim of the Model Y available in China.
Model Y L demand
Launched in August and first delivered in September, the Model Y L seems to be gaining momentum among Chinese EV buyers who are looking for added space and flexibility in their family vehicles. The Model Y L features a six-seat configuration with a very comfortable second row and a third row that fits regular-sized adults. This makes it a good all-around family car.
While the initial weeks of Model Y L insurance registrations were quite low, the vehicle’s registrations have been picking up in recent weeks. As per recent reports, the Model Y L’s volumes have been growing so much that the vehicle has helped boost Tesla China’s wholesale numbers in September. Even more Model Y L units would likely be registered this October.
Strong local momentum
The Model Y L’s sellout streak highlights Tesla China’s continued strength in the world’s most competitive EV market. With new orders now having an estimated delivery date of December, it seems all but certain that Tesla China would be selling every Model Y L it produces this fourth quarter. This could then help bolster the company’s numbers this Q4 2025.
The Model Y L is only being sold in China for now, though the vehicle’s features and size would actually make it very competitive in markets where larger family EVs are in high demand. Priced from RMB 339,000 ($47,180), the crossover offers a blend of performance, practicality, and value that has seemingly struck a chord with consumers, both in China and potentially, even abroad.
Tesla rival Xpeng’s flying car unit has been rebranded as Aridge, and it recently showed off its new flying car concept that has 500 kilometers (310 miles) of range and can travel at speeds of up to 360 kilometers per hour (224 MPH).
In Dubai earlier this week, Abridge showed off its new High-Speed Long-Range Full Tilt-Rotor Flying Car, which it aims to release in the Middle East as soon as 2027.
CEO and Vice President Du Chao said at the event on Monday that Aridge will pioneer new categories of flying cars under the brand, which was formerly called Aeroht. Aridge will focus on delivering cutting-edge, low-altitude products, aiming to make these types of aircraft more popular in the coming years.
At the event in Dubai, Aridge showcased its Land Aircraft Carrier, which completed the first overseas public demonstration of a manned flight for the modular flying car, CNEV Post reported.
Credit: Aridge
So far, it has already accumulated 7,000 cumulative orders for the vehicle. 600 of them are going to the United Arab Emirates’ Ali & Sons Group, Qatar’s Almana Group, Kuwait’s AlSayer, and the Chinese General Chamber of Commerce UAE.
It was not the only thing Aridge showcased at the event, either. It also has a long-range hybrid flying car called the A868. This is the concept with the 500-kilometer (310-mile) range rating and the 360 kilometers per hour (224 MPH) top speed.
Credit: Aridge
The A868 will target long-distance travel needs for consumers and will work alongside the Land Aircraft Carrier to build diversified low-altitude application scenarios that would be beneficial from a civilian and commercial standpoint.
The vehicles will be built at a new facility that was completed at the end of September, which is located in Guangzhou. It will be able to build 10,000 units with full-scale production and delivery scheduled to take off in 2026.
News
Tesla ramps production of its ‘new’ models at Giga Texas
The vehicles are being built at Tesla Gigafactory Texas in Austin, and there are plenty of units being built at the factory, based on a recent flyover by drone operator and plant observer Joe Tegtmeyer.
Tesla is ramping up production of its ‘new’ Model Y Standard at Gigafactory Texas just over a week after it first announced the vehicle on October 7.
Earlier this month, Tesla launched the Tesla Model 3 and Model Y “Standard,” their release of what it calls its affordable models. They are priced under $40,000, and although there was some noise surrounding the skepticism that they’re actually “affordable,” it appears things have been moving in the right direction.
The vehicles are being built at Tesla Gigafactory Texas in Austin, and there are plenty of units being built at the factory, based on a recent flyover by drone operator and plant observer Joe Tegtmeyer:
News: the @Tesla Model Y Standard production is well underway at Giga Texas today!
This consistent with what I was told to expect during the unveiling day last week!
The outbound lot had many Premium Model Y’s and @cybertruck too!
More coming soon! pic.twitter.com/WU489QKPLB
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) October 16, 2025
The new Standard Tesla models are technically the company’s response to losing the $7,500 EV tax credit, which significantly impacts any company manufacturing electric vehicles.
However, it seems the loss of the credit is impacting others much more than it is Tesla.
As General Motors and Ford are scaling back their EV efforts because it is beginning to hurt their checkbooks, Tesla is moving forward with its roadmap to catalyze annual growth from a delivery perspective. While GM, Ford, and Stellantis are all known for their vehicles, Tesla is known for its prowess as a car company, an AI company, and a Robotics entity.
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Tesla should have other vehicles coming in the next few years, especially as the Cybercab is evidently moving along with its preliminary processes, like crash testing and overall operational assessment.
It has been spotted at the Fremont Factory several times over the past couple of weeks, hinting that the vehicle could begin production sometime next year.
Tesla extends Model Y L delivery estimates to December 2025
Tesla rival Xpeng shows off new flying car concept for 2027 release
Tesla ramps production of its ‘new’ models at Giga Texas
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