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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
SpaceX to launch Starlink V2 satellites on Starship starting 2027
The update was shared by SpaceX President Gwynne Shotwell and Starlink Vice President Mike Nicolls.
SpaceX is looking to start launching its next-generation Starlink V2 satellites in mid-2027 using Starship.
The update was shared by SpaceX President Gwynne Shotwell and Starlink Vice President Mike Nicolls during remarks at Mobile World Congress (MWC) in Barcelona, Spain.
“With Starship, we’ll be able to deploy the constellation very quickly,” Nicolls stated. “Our goal is to deploy a constellation capable of providing global and contiguous coverage within six months, and that’s roughly 1,200 satellites.”
Nicolls added that once Starship is operational, it will be capable of launching approximately 50 of the larger, more powerful Starlink satellites at a time, as noted in a Bloomberg News report.
The initial deployment of roughly 1,200 next-generation satellites is intended to establish global and contiguous coverage. After that phase, SpaceX plans to continue expanding the system to reach “truly global coverage, including the polar regions,” Nicolls said.
Currently, all Starlink satellites are launched on SpaceX’s Falcon 9 rocket. The next-generation fleet will rely on Starship, which remains in development following a series of test flights in 2025. SpaceX is targeting its next Starship test flight, featuring an upgraded version of the rocket, as soon as this month.
Starlink is currently the largest satellite network in orbit, with nearly 10,000 satellites deployed. Bloomberg Intelligence estimates the business could generate approximately $9 billion in revenue for SpaceX in 2026.
Nicolls also confirmed that SpaceX is rebranding its direct-to-cell service as Starlink Mobile.
The service currently operates with 650 satellites capable of connecting directly to smartphones and has approximately 10 million monthly active users. SpaceX expects that figure to exceed 25 million monthly active users by the end of 2026.
Elon Musk
Elon Musk’s xAI and X to pay off $17.5B debt in full: report
The update was shared initially in a report from Bloomberg News, which cited people reportedly familiar with the matter.
Elon Musk’s social platform X and artificial intelligence startup xAI are reportedly preparing to repay approximately $17.5 billion in outstanding debt in full.
The update was shared initially in a report from Bloomberg News, which cited people reportedly familiar with the matter.
Morgan Stanley, which arranged the debt financing for both companies, has reportedly informed existing lenders that X and xAI plan to pay back the full amount of the $17.5 billion debt. Bloomberg’s sources did not disclose where the capital for the repayment would be coming from.
X, formerly known as Twitter, assumed roughly $12.5 billion in debt during Musk’s acquisition of the company. xAI separately borrowed about $5 billion through bonds and loans last June. The two firms merged last year under xAI Holdings.
Bloomberg noted that portions of the debt are relatively recent and may carry early repayment penalties. xAI’s $3 billion in high-yield bonds are expected to be redeemed at 117 cents on the dollar, reflecting a premium since the debt was expected to stay outstanding for at least two years.
X has been servicing tens of millions of dollars in monthly debt payments, while xAI has reportedly been burning approximately $1 billion in cash per month as it invests heavily in data centers, chips, and AI talent. That being said, xAI also concluded a funding round in January, where it raised $20 billion of new equity.
The repayment plans come as Musk consolidates several of his businesses. SpaceX recently acquired xAI, making it a subsidiary as the company explores plans for space-based data centers. The combined entity has been valued at approximately $1.25 trillion.
Bloomberg previously reported that SpaceX is targeting a confidential IPO filing as soon as this month, potentially positioning the private space firm for a public listing later this year. Representatives for Morgan Stanley declined to comment, and X and xAI did not immediately respond to requests for comment.
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Tesla Giga Berlin head calls out Handelsblatt’s claimed 2025 production figures
Andre Thierig, Senior Director of Manufacturing at Giga Berlin, published a detailed post on LinkedIn challenging several points made in the publication’s coverage of the Grünheide facility.
Tesla Gigafactory Berlin’s plant manager has publicly pushed back against recent reporting by German business publication Handelsblatt, which cited reportedly erroneous data about the factory’s production figures and financial performance.
Andre Thierig, Senior Director of Manufacturing at Giga Berlin, published a detailed post on LinkedIn challenging several points made in the publication’s coverage of the Grünheide facility.
In his LinkedIn post, Thierig called out Handelsblatt’s claim that 149,000 Model Y vehicles were produced at Giga Berlin in 2025. He noted that “the article is simply filled from front to back with false information and claims!
“I have to set the record straight here! In the last article about Tesla in Grünheide, the Handelsblatt speaks e.g. of 149,000 Model Ys built in 2025. WRONG!
“In 2025, we again produced over 200,000 vehicles. And this despite the fact that we stopped production in Q1 for the changeover to the new Model Y and then ramped it up again to 5,000 units per week over several weeks,” Thierig wrote.
He added that production increased each quarter in 2025 compared to the prior quarter and stated that more than 700,000 Model Y units have been produced at Grünheide since manufacturing began in 2022. For the first quarter of 2026, he stated that the factory is planning another production increase compared to the fourth quarter of 2025.
Thierig also questioned Handelsblatt’s reported 0.74% profit margin, writing that how the publication calculated the figure “remains reserved for their secret ‘calculation skills.’”
Beyond production data, Thierig highlighted Tesla’s broader footprint in Germany, stating that the company has invested more than €5 billion in Grünheide since 2020 and created nearly 11,000 permanent, above-tariff jobs. He added that Tesla is currently investing nearly €100 million into battery cell production at the site, which is expected to generate several hundred additional positions.
In a follow-up comment, Thierig noted that he did communicate with the publication’s editor-in-chief in an effort to “start fresh,” but he was informed that Handelsblatt’s current approach works just fine.
“Last year, I spoke to a representative of the Handelsblatt editor-in-chief and suggested that we “start anew” again. Handelsblatt turned down this offer on the grounds that their current approach works well for them,” Thierig noted.
Sönke Iwersen, Head of Investigative Research at Handelsblatt, responded to Thierig’s post, stating that the newspaper’s figures were based on Tesla’s own annual financial statements for the Grünheide entity.
He cited reported 2024 revenue of €7.68 billion, operating profit of €156.8 million, and net income after taxes of €55.6 million. Iwersen also referenced prior public comments from Elon Musk about Cybertruck demand, noting the gap between reported pre-orders and subsequent annual sales figures.
He also stated that the works council election eligibility figures Giga Berlin had dropped to 10,703 employees today from 12,415 two years ago.
“As far as production figures are concerned, these are figures from the data service provider Inovev. This is also stated in the article. Please compare this with Elon Musk’s information on demand for the Cybertruck. According to Musk, there were one million pre-orders. In the first year, 39,000 units were sold, in the second year 20,000. How can this be explained? With a million pre-orders?
“You yourself have repeatedly pointed out in recent months that no jobs would be cut in Grünheide because Tesla is different from the competition. Now a new works council is being elected in Grünheide. 10,703 people are eligible to vote. Two years ago, 12,415 people were eligible to vote. So there were exactly 1712 fewer from 2024 to 2026,” Iwersen wrote.
SpaceX to launch Starlink V2 satellites on Starship starting 2027
Elon Musk’s xAI and X to pay off $17.5B debt in full: report
