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Tesla Model Y welding efficiencies paves way to better build quality, top safety rating
Tesla CEO Elon Musk said the Model Y would be the safest midsized SUV on the road when it was unveiled in March 2019. Sandy Munro’s 11th episode of his Model Y breakdown series shows how the vehicle’s weld quality, added foam reinforcements, and “aluminum crush plate” could solidify Musk’s claims about the vehicle’s safety, while opening the doors towards better build quality.
Munro states the company’s focus on one welding technique has left him with nothing but positive remarks about the vehicle’s build quality. “The distancing is great. The edge is perfect. This is the kind of stuff that any car company…would be happy to have these kinds of welds all the way around,” he said.
The Model 3’s weld techniques were discussed during Munro’s teardown of the sedan in 2018 when he criticized Tesla’s use of multiple weld techniques. After stating the Model 3’s welding made it look like “a science project,” Munro claims the use of a single technique would have allowed for a more consistent build quality throughout the vehicle.
True to form, Tesla appears to have taken Munro’s suggestion for the Model Y. Tesla was consistent with the Model Y’s welds, and it surely impressed Munro. The electric car maker also used self-piercing rivets, or SPRs, to join dissimilar materials, like steel and aluminum. These two materials are present on the rear door flange welds, making for a quality build on the vehicle’s door frames.
Additionally, Tesla installed head impact countermeasures, or HICs, on several locations. These are used to soften the blow in the event of an accident where a passenger’s head collides off of a portion of the vehicle’s interior. Tesla’s decision to add this was a nice touch in Munro’s opinion, as it only increases the safety of the vehicle.
The Model Y is also equipped with a unique piece of aluminum in the upper lip of the trunk. Munro calls it the “aluminum rear crush plate/bracket.” The part holds the outer portions of the chassis together. The piece also is responsible for folding in the event of a rear collision.
This increases not only safety but also cost-effectiveness if an accident occurs because it will keep the outer frame of the vehicle from being compromised, Munro says. It is easy to remove thanks to a few bolts that are visible and readily accessible, and would also save a driver perhaps hundreds of dollars in labor costs at a shop. “If I hit a pole, it will cost me a few bucks, but it won’t cost me the whole damn car,” Munro jokes.
Under the rear seats, Tesla has installed not only EPP foam, which offers cost-efficiency and effectiveness, but also the Model 3’s floor cover plate. This is used to hold the rear seating assembly in place and separate the cabin from the undercarriage of the car where the battery is fitted. Tesla’s utilization of this Model 3 part proved the part was perfect for the Model Y, and the company has plenty in its stock bin, saving them time and money throughout the manufacturing process of the new vehicle.
Tesla’s already high safety marks for the Model 3 were improved even further in the Model Y thanks to recommendations from Munro. The auto expert’s discontent with the Model 3’s welding eventually led to improvements in the Model Y’s build quality. Tesla’s decision to add other safety features could make the vehicle Tesla’s safest car yet. Just as Elon Musk said a year ago, the Model Y may very well be the most reliable midsize crossover available to consumers.
Watch Munro Live’s breakdown of the Model Y’s safety features below.
Tesla is lowering the monthly price of its Cybertruck Windshield Protection Plan from $35 to $25. The new rate will apply to the first payment on or after October 1, 2026. Tesla has told subscribers that all other benefits stay the same.
The plan covers unlimited repairs for chips and minor cracks on the front windshield. It also includes one full replacement every 12 months at no extra charge. Additional replacements in the same year carry a $100 deductible. Service is performed with Tesla glass and camera calibration, which matters because Autopilot and Full Self-Driving rely on those lenses behind the windshield.
Looks like Tesla is decreasing the Cybertruck windshield protection plan price from $35 to $25
Awesome https://t.co/MRlTU1XTbf pic.twitter.com/PWkMZt1H7G
— TESLARATI (@Teslarati) August 28, 2026
There is no long-term contract. Coverage applies only to the front glass and does not include collision, vandalism, or weather damage.
The Cybertruck’s large, complex windshield has been more expensive to replace than glass on Tesla’s cars, which is why the pickup started at a higher subscription price. The $10 monthly cut reduces the annual cost from $420 to $300. Tesla has not publicly explained the change. The timing coincides with a year of claims data after the plan was extended to the Cybertruck.
Tesla sells several related protection products as monthly subscriptions through the Tesla app. The Windshield Protection Plan is also offered on other models. Model 3 and Model Y currently cost $16 a month. Those passenger-car rates are unchanged in the latest Cybertruck notice.
The Wheel and Tire Protection Plan covers road-hazard damage such as potholes, nails, and debris. Repairs are unlimited. Each wheel or tire replacement appointment has a $25 deductible. Pricing varies by model and whether the vehicle is a Performance version. Tesla is raising some of those rates on the same October 1 date.
Reported examples include Model 3 Performance moving from $16 to $24 and Model Y Performance from $20 to $24. Cybertruck wheel-and-tire coverage has been listed at $20 a month for the standard configuration.
A separate Luxe Package bundles four years of windshield coverage, wheel-and-tire coverage, and recommended maintenance on certain new Model S, Model X, and Cyberbeast orders, although the Model S and X are now defunct.
Tesla also offers an Extended Service Agreement after the basic vehicle warranty ends. That product covers many Tesla-manufactured parts rather than glass or tires. Together, the plans give owners a menu of targeted, cancel-anytime coverage instead of relying only on auto insurance.
UPDATE: The number has now been updated to 45 units, up from 7!
Here we go! Tesla has just added another 38 Cybercabs to its Robotaxi fleet, bringing the total up to 45, according to the Texas DMV.
Robots on robots on robots! This Thursday’s launch event is gonna be awesome🤖🤖🤖 pic.twitter.com/3HF24rHK4T
— Sawyer Merritt (@SawyerMerritt) August 31, 2026
Tesla is bolstering its Cybercab fleet with the State of Texas’s regulatory bodies ahead of the planned launch of the all-electric ride-hailing vehicle this Thursday.
Seven purpose-built Tesla Cybercabs have been added to Texas’s official automated vehicle registry, appearing in the Texas Motor Carrier Credentialing System (TxMCCS) public lookup just three days before Tesla’s invite-only Cybercab launch event in Austin on September 3.
The records, visible through TxDMV’s Motor Carrier and Automated Motor Vehicle Operator Lookup, list seven 2026 Tesla Cybercabs under Tesla Robotaxi, LLC. Their VINs begin with the 5YJA prefix, distinct from the 7SAYG Model Y robotaxis that already dominate Tesla’s Texas fleet.
Community trackers that scrape the same public database recorded the new entries on August 31, bringing Tesla’s authorized Texas robotaxi total to 276 vehicles: 269 Model Ys and the seven Cybercabs:
🚨 There are now SEVEN Tesla Cybercabs registered with the state of Texas
We are just three days from Cybercab! pic.twitter.com/ndwhuFYsep
— TESLARATI (@Teslarati) August 31, 2026
Texas Senate Bill 2807, which took effect in late May 2026, created a self-certification framework for commercial Level 4 operations. Operators file through TxMCCS, attest to SAE Level 4 capability, maintain insurance, and keep an active vehicle list.
Tesla completed that process months earlier for its existing Model Y Robotaxi service, which has carried paying passengers in Austin, Dallas, Houston and other markets. Adding the Cybercabs to the same authorization means the new two-seat, steering-wheel-free vehicles are now legally recognized for commercial use on Texas roads.
The timing is deliberate as Tesla scheduled the September 3 event at its Austin campus after sending invitations to selected Robotaxi riders and other guests. The company has described the evening as a chance to “experience the future of full autonomy” and plans to livestream it.
Production Cybercabs, which lack pedals and a steering wheel, have been rolling off the Giga Texas line for months; some earlier examples still carried temporary driver controls for data collection. Registering a small fleet of the finished design immediately before the public event signals that Tesla intends to move the purpose-built vehicle from factory and test tracks into the same Robotaxi app already used by Model Y passengers.
The seven units remain a tiny fraction of Tesla’s overall Texas authorization and far smaller than competing fleets. Registration does not automatically equal unsupervised public rides; it is the legal prerequisite.
Still, the sudden appearance of Cybercab VINs in the state’s lookup system, after a year of Model Y-only listings, is the clearest official confirmation yet that Tesla’s dedicated robotaxi hardware is entering the regulatory pipeline at the same moment the company is preparing to show it to invited guests and a global livestream audience.
Whether those seven vehicles appear at the September 3 event or begin carrying passengers shortly afterward, their presence in TxMCCS marks a concrete regulatory step that has been anticipated since the Cybercab concept was first revealed.
Tesla has expanded the operational geofence for its driverless Robotaxi service in Austin, Texas, marking the first such increase in some time. The updated Service Area for Robotaxi in Austin now spans about 288 square miles and is roughly 9 percent larger than the previous boundary.
This incremental growth adds approximately 24 square miles of coverage, bringing the prior zone of roughly 264 square miles into a broader footprint that better serves northern suburbs.
The expansion extends the geofence northward toward Pflugerville along the US 183 corridor, incorporating additional neighborhoods north of the Domain and areas such as Mesa Park. These additions include higher-end residential and commercial districts that previously sat just outside the allowed operating zone.
Riders can now request unsupervised trips that begin or end in these newly included locations, provided the entire route remains inside the digital boundary:
Tesla has just expanded its Robotaxi service area in Austin, Texas for the first time in 10 months.
The new service area is roughly 9% larger than the old one, and is about 288 square miles in total. pic.twitter.com/i4oBM1KfWS
— Sawyer Merritt (@SawyerMerritt) August 31, 2026
Tesla first launched public Robotaxi operations in Austin in mid-2025 with a modest initial zone of about 20 square miles. Subsequent enlargements in 2025 and early 2026 steadily grew the map until it covered much of the metropolitan area.
After the last major update roughly ten months earlier, the company held the boundary steady while it collected additional miles and refined the FSD suite.
The modest nine percent increase still matters for daily utility. Longer trips become possible, more residents gain access, and the fleet can accumulate more diverse real-world data across new road types and traffic patterns. Observers note that the added territory aligns with existing Tesla service infrastructure, which could support more efficient vehicle staging in the North end of Austin.
Although the geofence has grown, Tesla continues to operate a relatively small unsupervised fleet in the city. The company has emphasized safety and software readiness over rapid geographic scaling. This latest map update signals that Tesla remains committed to expanding Robotaxi availability in its home market as it prepares for further software improvements and potential Cybercab deployments.
The 288-square-mile zone now gives Austin riders one of the larger driverless service areas currently available in the United States.
Tesla Cybertruck windshield protection just got cheaper
Tesla Cybercab fleet grows in Austin ahead of launch event
