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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 (NASDAQ: TSLA) will report its earnings for the second quarter of 2026 this evening after market close, and investors and analysts are waiting anxiously to see what the company will report for the second three-month span of the year.
Analysts have already put out their expectations from a financial standpoint for the company’s second quarter, but what’s unknown is what Tesla plans to discuss during the call.
Financial Expectations
Wall Street consensus expectations put Tesla’s Earnings Per Share (EPS) at $0.53, while revenues are expected to come in around $26.4 billion.
This would compare to an EPS of $0.39 and $22.19 billion compared to Tesla’s Q2 2025. Last quarter, EPS came in at $0.41 on $22.387 billion of revenue. Additionally in Q1, Tesla beat analyst expectations, but shares dropped over 3 percent the following trading day.
What We Expect
In terms of discussions, Tesla earnings are pretty sporadic and depend on a handful of things, including current events, investor questions, and more.
Tesla uses a platform called Say to field questions from investors and analysts. These questions are what will be used during the call. Here are the top 5 from the Retail side and top 3 from the Institutional side:
Retail:
“Tesla has missed short-term guidance on robotaxi 3 earnings reports in a row, from 50% coverage of USA by end of 2025 to most recently 7 new cities in 1H26. What is keeping Tesla back from accomplishing these short term goals that they’ve set for themselves?”
“What are the main constraints to expanding robotaxi operations faster, and how do you see that lining up with Cybercab production?”
“What’s the current status of Optimus Gen 3 production ramp, initial deployment in factories, and external sales timeline/volume for 2027? What tasks can we expect the Optimus to perform by end of 2027?”
“To reward long-term Tesla retail shareholders for their loyalty, can you commit to achieving at least half of the goals outlined in your 2025 compensation plan before considering any offers to acquire or merge Tesla?”
“Why has growth of robotaxi vehicles stalled? When will we see cybercab start customer rides?”
Institutional
“Previously, you’ve said Tesla would lead the R&D while SpaceX would lead production for Terafab. Can you provide an update on how that division of responsibilities is evolving, and any additional clarity on the expected capital contributions from Tesla and SpaceX?”
“For autonomous driving, Tesla’s fleet created a huge data advantage by collecting billions of real-world miles. That advantage doesn’t yet exist for Optimus. How should we think about data availability and its impact on Optimus development?”
“Why is it necessary to limit robotaxi operations within specific zones within cities to start? Will every city have to be rolled out this way?”
Tesla will report earnings for Q2 this evening with the Shareholder Deck at 4 p.m. ET, with the call starting around 5:30 p.m. ET.
Elon Musk
Elon Musk handed Grok something no other AI company can get their hands on
Elon Musk says SpaceX will feed engineering data into Grok’s next model, avoiding restricted material.
Elon Musk said Tuesday that SpaceX will feed its internal engineering data into the next major training run for Grok, the AI model now folded into SpaceX following February’s merger. In a post on X, Musk wrote that SpaceX’s “massive corpus of world-class engineering data,” excluding anything restricted under U.S. arms export law, will be added during supplemental training of what he called the “2T run,” a reference to a roughly two trillion parameter model that would nearly double the parameters behind the latest Grok 4.5 that’s rolling out.
SpaceX’s massive corpus of world-class engineering data (excluding material blocked by ITAR) will be added during supplemental training of the 2T run.
This will dramatically improve Grok’s engineering capabilities. https://t.co/BbQEViFByn
— Elon Musk (@elonmusk) July 21, 2026
The excluded material that Musk is referring to would fall under the International Traffic in Arms Regulations (ITAR), which restricts export of technical data tied to defense and space hardware. That likely rules out propulsion specifics for Merlin and Raptor engines along with guidance and control details for SpaceX’s launch vehicles, but leaves manufacturing knowledge, materials science, and Starlink hardware design on the table.
The announcement extends a pattern that has been building since SpaceX’s Nasdaq debut in June, when the company went public with Grok and xAI’s Colossus supercomputer folded into the pitch to investors.
Days after that listing, SpaceX closed its $60 billion all stock acquisition of coding startup Cursor, giving xAI both enterprise software distribution and a stream of real world developer data to train on. Grok 4.5 launched July 8 running partly on that Cursor training data, with Musk describing it as roughly comparable to Anthropic’s Opus 4.7 but faster and cheaper to run.
Feeding SpaceX’s own engineering data into the next AI model follows the same logic Musk has applied across xAI’s sister companies. Tesla supplies real world driving data and manufacturing expertise, X supplies conversational data, and now SpaceX supplies aerospace engineering data built up since 2002.
Musk did not give a release date for the upcoming AI model, referred to elsewhere as Grok 4.6. He has said the two trillion parameter run is in its final training phase and expected to wrap this week.
Tesla has extended its Bay Area ride-hailing service to include pickups and drop-offs at San Francisco International Airport (SFO). The update, shared via the company’s official channels on July 21, allows users in the region to request rides directly to and from one of California’s busiest airports.
The expansion builds on Tesla’s secured limousine permit for SFO operations. Public records show the permit became effective March 20, 2026, and remains active through January 31, 2027. Tesla vehicles operating the service now display authorized limousine permits issued by the City and County of San Francisco.
Our Bay Area rideshare service now goes to SFO ✈️
— Tesla AI (@Tesla_AI) July 21, 2026
Tesla’s ride-hailing program in California relies on Model Y vehicles equipped with Full Self-Driving (Supervised) technology. Human safety drivers remain present in compliance with state regulations, distinguishing the service from fully driverless operations.
The Bay Area geofence covers a broad area spanning north of San Francisco to south of San Jose, offering extensive connectivity across the region.
UPDATE: Elon Musk reveals why Tesla didn’t say ‘Robotaxi’ upon California launch
This SFO addition follows earlier progress at other Bay Area airports. Tesla previously expanded service to San Jose Mineta International Airport (SJC) in late 2025. The company had engaged with SFO, SJC, and Oakland International Airport officials as early as September 2025 to secure necessary approvals for passenger transport.
The service provides a new option for travelers seeking electric, app-based transportation integrated with Tesla’s ecosystem. Rides are booked through Tesla’s dedicated ride-hailing application, which handles matching, routing, and payments. Pricing follows standard ride-hailing models, with potential adjustments based on distance, time, and demand.
Tesla’s California ride-hailing program launched in July 2025 with an initial invite-only rollout in the Bay Area. It started alongside operations in Austin, Texas, marking the company’s second major U.S. market.
The Bay Area remains a primary focus in California, with service centered on high-demand corridors connecting residential, commercial, and now major transportation hubs. This latest airport integration represents a practical step in Tesla’s broader mobility ambitions within the state.
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