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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 has lost its Model Y Program Manager, he announced on LinkedIn, marking the second major departure from the company today.
Emmanuel Lamacchia has been in the role for 4 years and 7 months, responsible for the rollout of the all-electric crossover in several markets.
The Model Y became the best-selling vehicle in the world for two years under Lamacchia’s watch, making this a huge loss for the company. However, it seems the decision was made under Lamacchia’s own initiative.
He confirmed his decision on LinkedIn:
“After 8 incredible years, I’m moving on from Tesla.
What a journey it’s been… from leading NPI for Model 3 and Model Y variants to becoming the Vehicle Program Manager for Model Y, the best-selling car in the world!
Leading the All-New Model Y launch was the highlight: converting all 4 factories across 3 continents in just 2 weeks. Something that had never been done before in the auto industry.
To the teams who made this possible: you should be incredibly proud. This achievement belongs to you: the engineers, designers, buyers, and associates in Fremont, Shanghai, Berlin, and Austin who turned an impossible timeline into reality.
Grateful to the leaders who trusted me with programs that stretched my capabilities and to the cross-functional partners who showed me that great solutions come from collaboration, not hierarchy.
Tesla taught me how to move fast without breaking things and how to scale from prototypes to millions of units.
Excited for what’s next. More to share soon.”
It marks the second major program loss for Tesla today, as it also bid farewell to Cybertruck and Model 3 Program Manager Siddhant Awasthi, who said he left voluntarily in “one of the hardest decisions of his life.”
Lamacchia was at Tesla for just a shade under eight years, and previously worked for Rolls-Royce for roughly the same amount of time.
After the loss of both Lamacchia and Awasthi today, Tesla has lost a handful of key executives in 2025, including:
- David Imai, Director of Design
- David Lau, VP of Software Engineering
- Mark Westfall, Head of Mechanical Engineering
- Prashant Menon, Regional Director in India
- Vineet Mehta, Head of Battery Architecture
- Omead Afshar, VP/Head of Sales and Manufacturing in North America
- Milan Kovac, Head of Optimus Team
- Jenna Ferrua, Director of HR
- Troy Jones, VP of Sales, Service, and Delivery
- Pete Bannon, VP of Hardware Engineering
- Piero Landolfi, Director of Service
News
Tesla prepares to expand Giga Texas with new Optimus production plant
Drone operator Joe Tegtmeyer recognized Tesla construction crews performing ground leveling and clearing efforts at the plant earlier today.
Tesla is preparing to expand Gigafactory Texas once again with a brand new facility that will house the eventual manufacturing efforts for Optimus, its humanoid robot.
It is already building some units on a Pilot line at the Fremont Factory in Northern California, but Tesla is planning to build the vast majority of its Optimus project at Gigafactory Texas.
Tesla Optimus gets its latest job, and it’s not in the company’s factories
It will build one million units per year in Fremont, but CEO Elon Musk said the company would build 10 million units every year in Texas at a new building at Giga Texas.
Musk said:
“I think there could be tens of billions of Optimus robots out there. Um, now obviously it’s very important we pay close attention to safety here. Then a 10 million unit uh per year production line here the I don’t know where we’re going to put the 100 million unit production line. on Mars. Maybe on Mars, I don’t know.”
Evidently, Tesla is ready to begin thinking about the production efforts of Optimus beyond a theoretical standpoint and is starting to prepare for the construction of the manufacturing plant on Giga Texas property.
Drone operator Joe Tegtmeyer recognized Tesla construction crews performing ground leveling and clearing efforts at the plant earlier today:
Giga Texas News!
A brand-new, stand-alone factory is starting construction! This follows the Shareholders meeting & info that a 10-million-per-year @Tesla_Optimus production facility “on the Giga Texas campus” will be built & enter into production in 2027!
Here are some… pic.twitter.com/7ig5DohfOt
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) November 10, 2025
Production is still slated for 2027, at least at Gigafactory Texas. As previously mentioned, the company is building some units in Fremont for the time being, at least until subsequent versions of the Optimus project advance.
Tesla has done a great job of advancing Optimus forward, but it also has truly grand expectations for the project.
Musk said it could potentially be the biggest product in the history of the planet, as it will revolutionize the way humans perform tasks, probably eliminating monotonous tasks from everyday life.
Tesla revealed its first customer for the all-electric Semi truck after it launches next year. Who it truly is should not be a surprise.
The Semi is going to finally start deliveries to new companies outside of Tesla’s pilot program starting in 2026. The company has been building a dedicated production facility in Reno, Nevada, that has finally taken shape, but Tesla was evidently not finished with the Semi’s development.
Last week at the Annual Shareholder Meeting, Tesla said it had implemented some new designs into the Semi, helping with efficiency, updating its design, and making it a more suitable vehicle for hauling loads, as the changes also helped increase payload.
Tesla has obtained a lengthy list of companies that have committed to implementing the Semi in their own fleets, hoping to bring their logistics lineups up to date with electric powertrains and autonomous technologies.
While it is already operating a pilot program with PepsiCo. and Frito-Lay, Tesla will expand to other businesses, primarily using it internally after its launch.
Head of the Semi program at Tesla, Dan Priestley, said the company would be the first user of the vehicle after its launch next year. It has been using it to a certain extent, but the company has not been able to completely abandon gas haulers.
Instead, it will implement the Semi into its fleet for more sustainable vehicle logistics starting next year:
Tesla will be the first customer as we electrify our supply chain. This includes Texas operations.
— Dan Priestley (@danWpriestley) November 7, 2025
Tesla has already received orders for the Semi from a variety of large companies, including Walmart, Sysco, Anheuser-Busch, UPS, DHL, J.B. Hunt, among others.
Many analysts see the Tesla Semi as a major contributor to future growth and increasing value within the company, especially from a Wall Street perspective. Some firms say the Semi is one of several near and medium-term contributors to the company increasing its market cap.
Cantor Fitzgerald is just one of those firms, as last week it explicitly listed the Semi as a catalyst.
Analyst Andres Sheppard said, “Overall, we remain bullish on TSLA over the medium to long term. We continue to see meaningful future upside from Energy Storage & Deployment, FSD, Robotaxis/Cybercab, Semis, and Optimus Bots.”
Tesla loses Model Y program manager in second blow in single day
Tesla prepares to expand Giga Texas with new Optimus production plant
Tesla reveals its first Semi customer after launch
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