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 Model S completes first ever FSD Cannonball Run with zero interventions
The coast-to-coast drive marked the first time Tesla’s FSD system completed the iconic, 3,000-mile route end to end with no interventions.
A Tesla Model S has completed the first-ever full Cannonball Run using Full Self-Driving (FSD), traveling from Los Angeles to New York with zero interventions. The coast-to-coast drive marked the first time Tesla’s FSD system completed the iconic, 3,000-mile route end to end, fulfilling a long-discussed benchmark for autonomy.
A full FSD Cannonball Run
As per a report from The Drive, a 2024 Tesla Model S with AI4 and FSD v14.2.2.3 completed the 3,081-mile trip from Redondo Beach in Los Angeles to midtown Manhattan in New York City. The drive was completed by Alex Roy, a former automotive journalist and investor, along with a small team of autonomy experts.
Roy said FSD handled all driving tasks for the entirety of the route, including highway cruising, lane changes, navigation, and adverse weather conditions. The trip took a total of 58 hours and 22 minutes at an average speed of 64 mph, and about 10 hours were spent charging the vehicle. In later comments, Roy noted that he and his team cleaned out the Model S’ cameras during their stops to keep FSD’s performance optimal.
History made
The historic trip was quite impressive, considering that the journey was in the middle of winter. This meant that FSD didn’t just deal with other cars on the road. The vehicle also had to handle extreme cold, snow, ice, slush, and rain.
As per Roy in a post on X, FSD performed so well during the trip that the journey would have been completed faster if the Model S did not have people onboard. “Elon Musk was right. Once an autonomous vehicle is mature, most human input is error. A comedy of human errors added hours and hundreds of miles, but FSD stunned us with its consistent and comfortable behavior,” Roy wrote in a post on X.
Roy’s comments are quite notable as he has previously attempted Cannonball Runs using FSD on December 2024 and February 2025. Neither were zero intervention drives.
Elon Musk
Tesla removes Autopilot as standard, receives criticism online
The move leaves only Traffic Aware Cruise Control as standard equipment on new Tesla orders.
Tesla removed its basic Autopilot package as a standard feature in the United States. The move leaves only Traffic Aware Cruise Control as standard equipment on new Tesla orders, and shifts the company’s strategy towards paid Full Self-Driving subscriptions.
Tesla removes Autopilot
As per observations from the electric vehicle community on social media, Tesla no longer lists Autopilot as standard in its vehicles in the U.S. This suggests that features such as lane-centering and Autosteer have been removed as standard equipment. Previously, most Tesla vehicles came with Autopilot by default, which offers Traffic-Aware Cruise Control and Autosteer.
The change resulted in backlash from some Tesla owners and EV observers, particularly as competing automakers, including mainstream players like Toyota, offer features like lane-centering as standard on many models, including budget vehicles.
That being said, the removal of Autopilot suggests that Tesla is concentrating its autonomy roadmap around FSD subscriptions rather than bundled driver-assistance features. It would be interesting to see how Tesla manages its vehicles’ standard safety features, as it seems out of character for Tesla to make its cars less safe over time.
Musk announces FSD price increases
Following the Autopilot changes, Elon Musk stated on X that Tesla is planning to raise subscription prices for FSD as its capabilities improve. In a post on X, Musk stated that the current $99-per-month price for supervised FSD would increase over time, especially as the system itself becomes more robust.
“I should also mention that the $99/month for supervised FSD will rise as FSD’s capabilities improve. The massive value jump is when you can be on your phone or sleeping for the entire ride (Unsupervised FSD),” Musk wrote.
At the time of his recent post, Tesla still offers FSD as a one-time purchase for $8,000, but Elon Musk has confirmed that this option will be discontinued on February 14, leaving subscriptions as the only way to access the system.
Tesla has initiated Cybertruck deliveries in a new region for the first time, as the all-electric pickup has officially made its way to the United Arab Emirates, marking the newest territory to receive the polarizing truck.
Tesla launched orders for the Cybertruck in the Middle East back in September 2025, just months after the company confirmed that it planned to launch the pickup in the region, which happened in April.
I took a Tesla Cybertruck weekend Demo Drive – Here’s what I learned
By early October, Tesla launched the Cybertruck configurator in the United Arab Emirates, Qatar, and Saudi Arabia, with pricing starting at around AED 404,900, or about $110,000 for the Dual Motor configuration.
This decision positioned the Gulf states as key early international markets, and Tesla was hoping to get the Cybertruck outside of North America for the first time, as it has still been tough to launch in other popular EV markets, like Europe and Asia.
By late 2025, Tesla had pushed delivery timelines slightly and aimed for an early 2026 delivery launch in the Middle East. The first official customer deliveries started this month, and a notable handover event occurred in Dubai’s Al Marmoom desert area, featuring a light and fire show.
Around 63 Cybertrucks made their way to customers during the event:
First @cybertruck deliveries in the UAE 🇦🇪 pic.twitter.com/sN2rAxppUA
— Tesla Europe & Middle East (@teslaeurope) January 22, 2026
As of this month, the Cybertruck still remains available for configuration on Tesla’s websites for the UAE, Saudi Arabia, Qatar, and other Middle Eastern countries like Jordan and Israel. Deliveries are rolling out progressively, with the UAE leading as the first to see hands-on customer events.
In other markets, most notably Europe, there are still plenty of regulatory hurdles that Tesla is hoping to work through, but they may never be resolved. The issues come from the unique design features that conflict with the European Union’s (EU) stringent safety standards.
These standards include pedestrian protection regulations, which require vehicles to minimize injury risks in collisions. However, the Cybertruck features sharp edges and an ultra-hard stainless steel exoskeleton, and its rigid structure is seen as non-compliant with the EU’s list of preferred designs.
The vehicle’s gross weight is also above the 3.5-tonne threshold for standard vehicles, which has prompted Tesla to consider a more compact design. However, the company’s focus on autonomy and Robotaxi has likely pushed that out of the realm of possibility.
For now, Tesla will work with the governments that want it to succeed in their region, and the Middle East has been a great partner to the company with the launch of the Cybertruck.
Tesla Model S completes first ever FSD Cannonball Run with zero interventions
Tesla removes Autopilot as standard, receives criticism online
