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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.
Elon Musk
Tesla confirmed HW3 can’t do Unsupervised FSD but there’s more to the story
Tesla confirmed HW3 vehicles cannot run unsupervised FSD, replacing its free upgrade promise with a discounted trade-in.
Tesla has officially confirmed that early vehicles with its Autopilot Hardware 3 (HW3) will not be capable of unsupervised Full Self-Driving, while extending a path forward for legacy owners through a discounted trade-in program. The announcement came by way of Elon Musk in today’s Tesla Q1 2026 earnings call.
🚨 Our LIVE updates on the Tesla Earnings Call will take place here in a thread 🧵
Follow along below: pic.twitter.com/hzJeBitzJU
— TESLARATI (@Teslarati) April 22, 2026
The history here matters. HW3 launched in April 2019, and Tesla sold Full Self-Driving packages to owners on the understanding that the hardware was sufficient for full autonomy. Some owners paid between $8,000 and $15,000 for FSD during that period. For years, as FSD’s AI models grew more demanding, HW3 vehicles fell progressively further behind, eventually landing on FSD v12.6 in January 2025 while AI4 vehicles moved to v13 and then v14. When Musk acknowledged in January 2025 that HW3 simply could not reach unsupervised operation, and alluded to a difficult hardware retrofit.
The near-term offering is more concrete. Tesla’s head of Autopilot Ashok Elluswamy confirmed on today’s call that a V14-lite will be coming to HW3 vehicles in late June, bringing all the V14 features currently running on AI4 hardware. That is a meaningful software update for owners who have been frozen at v12.6 for over a year, and it represents genuine effort to keep older hardware relevant. Unsupervised FSD for vehicles is now targeted for Q4 2026 at the earliest, with Musk describing it as a gradual, geography-limited rollout.
For HW3 owners, the over-the-air V14-lite update is welcomed, and the discounted trade-in path at least acknowledges an old obligation. What happens next with the trade-in pricing will define how this chapter ultimately gets written. If Tesla prices the hardware path fairly, acknowledges what early adopters are owed, and delivers V14-lite on the June timeline it committed to today, it has a real opportunity to convert one of the longest-running sore subjects among early adopters into a loyalty story.
Elon Musk
Tesla isn’t joking about building Optimus at an industrial scale: Here we go
Tesla’s Optimus factory in Texas targets 10 million robots yearly, with 5.2 million square feet under construction.
Tesla’s Q1 2026 Update Letter, released today, confirms that first generation Optimus production lines are now well underway at its Fremont, California factory, with a pilot line targeting one million robots per year to start. Of bigger note is a shared aerial image of a large piece of land adjacent to Gigafactory Texas, that Tesla has prominently labeled “Optimus factory site preparation.”
Permit documents show Tesla is seeking to add over 5.2 million square feet of new building space to the Giga Texas North Campus by the end of 2026, at an estimated construction investment of $5 billion to $10 billion. The longer term production target for that facility is 10 million Optimus units per year. Giga Texas already sits on 2,500 acres with over 10 million square feet of existing factory floor, and the North Campus expansion is being built to support multiple projects, including the dedicated Optimus factory, the Terafab chip fabrication facility (a joint Tesla/SpaceX/xAI venture), a Cybercab test track, road infrastructure, and supporting facilities.
Credit: TESLA
Texas makes strategic sense beyond the existing infrastructure. The state’s tax structure, lower labor costs relative to California, and the proximity to Tesla’s AI training cluster Cortex 1 and 2, both located at Giga Texas and now totaling over 230,000 H100 equivalent GPUs, means the Optimus software stack and the factory producing the hardware will share the same campus. Tesla’s Q1 report also confirmed completion of the AI5 chip tape out in April, the inference processor designed specifically to power Optimus units in the field.
As Teslarati reported, the Texas facility is intended to house Optimus V4 production at full scale. Musk told the World Economic Forum in January that Tesla plans to sell Optimus to the public by end of 2027 at a price between $20,000 and $30,000, stating, “I think everyone on earth is going to have one and want one.” He has previously pegged long term demand for general purpose humanoid robots at over 20 billion units globally, citing both consumer and industrial use cases.
Tesla (NASDAQ: TSLA) reported its earnings for the first quarter of 2026 on Wednesday afternoon. Here’s what the company reported compared to what Wall Street analysts expected.
The earnings results come after Tesla reported a miss on vehicle deliveries for the first quarter, delivering 358,023 vehicles and building 408,386 cars during the three-month span.
As Tesla transitions more toward AI and sees itself as less of a car company, expectations for deliveries will begin to become less of a central point in the consensus of how the quarter is perceived.
Nevertheless, Tesla is leaning on its strong foundation as a car company to carry forward its AI ambitions. The first quarter is a good ground layer for the rest of the year.
Tesla Q1 2026 Earnings Results
Tesla’s Earnings Results are as follows:
- Non-GAAP EPS –Â $0.41 Reported vs. $0.36 Expected
- Revenues –Â $22.387 billion vs. $22.35 billion Expected
- Free Cash Flow –Â $1.444 billion
- Profit –Â $4.72 billion
Tesla beat analyst expectations, so it will be interesting to see how the stock responds. IN the past, we’ve seen Tesla beat analyst expectations considerably, followed by a sharp drop in stock price.
On the same token, we’ve seen Tesla miss and the stock price go up the following trading session.
Tesla will hold its Q1 2026 Earnings Call in about 90 minutes at 5:30 p.m. on the East Coast. Remarks will be made by CEO Elon Musk and other executives, who will shed some light on the investor questions that we covered earlier this week.
You can stream it below. Additionally, we will be doing our Live Blog on X and Facebook.
Q1 2026 Earnings Call at 4:30pm CT https://t.co/pkYIaGJ32y
— Tesla (@Tesla) April 22, 2026
Tesla confirmed HW3 can’t do Unsupervised FSD but there’s more to the story
Tesla isn’t joking about building Optimus at an industrial scale: Here we go
