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.
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News
Tesla Model 3 named New Zealand’s best passenger car of 2025
Tesla flipped the switch on Full Self-Driving (Supervised) in September, turning every Model 3 and Model Y into New Zealand’s most advanced production car overnight.
The refreshed Tesla Model 3 has won the DRIVEN Car Guide AA Insurance NZ Car of the Year 2025 award in the Passenger Car category, beating all traditional and electric rivals.
Judges praised the all-electric sedan’s driving dynamics, value-packed EV tech, and the game-changing addition of Full Self-Driving (Supervised) that went live in New Zealand this September.
Why the Model 3 clinched the crown
DRIVEN admitted they were late to the “Highland” party because the updated sedan arrived in New Zealand as a 2024 model, just before the new Model Y stole the headlines. Yet two things forced a re-evaluation this year.
First, experiencing the new Model Y reminded testers how many big upgrades originated in the Model 3, such as the smoother ride, quieter cabin, ventilated seats, rear touchscreen, and stalk-less minimalist interior. Second, and far more importantly, Tesla flipped the switch on Full Self-Driving (Supervised) in September, turning every Model 3 and Model Y into New Zealand’s most advanced production car overnight.
FSD changes everything for Kiwi buyers
The publication called the entry-level rear-wheel-drive version “good to drive and represents a lot of EV technology for the money,” but highlighted that FSD elevates it into another league. “Make no mistake, despite the ‘Supervised’ bit in the name that requires you to remain ready to take control, it’s autonomous and very capable in some surprisingly tricky scenarios,” the review stated.
-->At NZ$11,400, FSD is far from cheap, but Tesla also offers FSD (Supervised) on a $159 monthly subscription, making the tech accessible without the full upfront investment. That’s a game-changer, as it allows users to access the company’s most advanced system without forking over a huge amount of money.
News
Tesla starts rolling out FSD V14.2.1 to AI4 vehicles including Cybertruck
FSD V14.2.1 was released just about a week after the initial FSD V14.2 update was rolled out.
It appears that the Tesla AI team burned the midnight oil, allowing them to release FSD V14.2.1 on Thanksgiving. The update has been reported by Tesla owners with AI4 vehicles, as well as Cybertruck owners.
For the Tesla AI team, at least, it appears that work really does not stop.
FSD V14.2.1
Initial posts about FSD V14.2.1 were shared by Tesla owners on social media platform X. As per the Tesla owners, V14.2.1 appears to be a point update that’s designed to polish the features and capacities that have been available in FSD V14. A look at the release notes for FSD V14.2.1, however, shows that an extra line has been added.
“Camera visibility can lead to increased attention monitoring sensitivity.”
Whether this could lead to more drivers being alerted to pay attention to the roads more remains to be seen. This would likely become evident as soon as the first batch of videos from Tesla owners who received V14.21 start sharing their first drive impressions of the update. Despite the update being released on Thanksgiving, it would not be surprising if first impressions videos of FSD V14.2.1 are shared today, just the same.
-->Rapid FSD releases
What is rather interesting and impressive is the fact that FSD V14.2.1 was released just about a week after the initial FSD V14.2 update was rolled out. This bodes well for Tesla’s FSD users, especially since CEO Elon Musk has stated in the past that the V14.2 series will be for “widespread use.”
FSD V14 has so far received numerous positive reviews from Tesla owners, with numerous drivers noting that the system now drives better than most human drivers because it is cautious, confident, and considerate at the same time. The only question now, really, is if the V14.2 series does make it to the company’s wide FSD fleet, which is still populated by numerous HW3 vehicles.
News
Waymo rider data hints that Tesla’s Cybercab strategy might be the smartest, after all
These observations all but validate Tesla’s controversial two-seat Cybercab strategy, which has caught a lot of criticism since it was unveiled last year.
Toyota Connected Europe designer Karim Dia Toubajie has highlighted a particular trend that became evident in Waymo’s Q3 2025 occupancy stats. As it turned out, 90% of the trips taken by the driverless taxis carried two or fewer passengers.
These observations all but validate Tesla’s controversial two-seat Cybercab strategy, which has caught a lot of criticism since it was unveiled last year.
Toyota designer observes a trend
Karim Dia Toubajie, Lead Product Designer (Sustainable Mobility) at Toyota Connected Europe, analyzed Waymo’s latest California Public Utilities Commission filings and posted the results on LinkedIn this week.
“90% of robotaxi trips have 2 or less passengers, so why are we using 5-seater vehicles?” Toubajie asked. He continued: “90% of trips have 2 or less people, 75% of trips have 1 or less people.” He accompanied his comments with a graphic showing Waymo’s occupancy rates, which showed 71% of trips having one passenger, 15% of trips having two passengers, 6% of trips having three passengers, 5% of trips having zero passengers, and only 3% of trips having four passengers.
The data excludes operational trips like depot runs or charging, though Toubajie pointed out that most of the time, Waymo’s massive self-driving taxis are really just transporting 1 or 2 people, at times even no passengers at all. “This means that most of the time, the vehicle being used significantly outweighs the needs of the trip,” the Toyota designer wrote in his post.
-->Cybercab suddenly looks perfectly sized
Toubajie gave a nod to Tesla’s approach. “The Tesla Cybercab announced in 2024, is a 2-seater robotaxi with a 50kWh battery but I still believe this is on the larger side of what’s required for most trips,” he wrote.
With Waymo’s own numbers now proving 90% of demand fits two seats or fewer, the wheel-less, lidar-free Cybercab now looks like the smartest play in the room. The Cybercab is designed to be easy to produce, with CEO Elon Musk commenting that its product line would resemble a consumer electronics factory more than an automotive plant. This means that the Cybercab could saturate the roads quickly once it is deployed.
While the Cybercab will likely take the lion’s share of Tesla’s ride-hailing passengers, the Model 3 sedan and Model Y crossover would be perfect for the remaining 9% of riders who require larger vehicles. This should be easy to implement for Tesla, as the Model Y and Model 3 are both mass-market vehicles.
Tesla Model 3 named New Zealand’s best passenger car of 2025
Tesla starts rolling out FSD V14.2.1 to AI4 vehicles including Cybertruck
