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Tesla’s ‘skunkworks lab’ for its custom battery cell pilot production line is growing

(Credit: CNBC)

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Tesla’s Battery Day may still be a couple of months away, but hints about the highly-anticipated event’s details are already abounding. With Elon Musk specifically mentioning that the event will be held in Fremont, and that it will include a tour of the company’s pilot battery cell production line, it appears that previous reports, which point to a “skunkworks lab” in the city, were accurate. What’s more, documents filed by the electric car maker in previous months seem to indicate that its mysterious pilot battery cell facility is growing. 

Initial leaks and reports about Tesla’s mysterious “skunkworks lab” were posted as early as June 2019, with a CNBC article stating that the facility is located at Kato Road, just a few minutes away from the Fremont factory, where the Model S, Model 3, Model X, and Model Y are built. Citing former and current Tesla employees, the news agency stated that Tesla’s R&D teams were focused on prototyping and designing advanced lithium-ion batteries, as well as new equipment and processes that could usher in the mass production of the next-gen cells. 

These batteries are now widely speculated to be the million-mile battery that has been mentioned by the company. The million-mile battery is a significant part of Tesla’s game plan, being the one defining factor that could help electric vehicles achieve price parity with gas powered cars, and allow battery storage devices to last decades when deployed. Amidst the wait for Battery Day, speculations are abounding that Tesla will be conducting a deep dive into its million-mile batteries during the event, similar to how Autonomy Day included an in-depth discussion on the company’s custom Hardware 3.0 computer. 

Tesla’s 2170 battery cells. (Credit: Tesla)

As it turned out, Tesla’s skunkworks lab at Kato Road has been very busy this year. A proposal submitted last March, for example, outlines plans to redevelop the existing site by adding floors to the facility. According to Tesla, the redesigned building will be housing 45 research and development employees and up to 425 manufacturing workers that are spread through several shifts from Monday through Friday. This appears to suggest that the company, as early as March this year, was looking to ramp the battery cell output of its pilot production line. 

Interestingly enough, Tesla has also been posting multiple job listings on its Careers page that were specifically focused on battery cell manufacturing. By May 2020, Tesla had posted job listings for Cell Engineers, Production Process Engineers, and Controls Engineers. A look at these listings would show references to a battery cell manufacturing operations, and as luck would have it, the posts listed Fremont, California as their location. 

Further documents show that Tesla had also requested to increase its power demand by 6 MW, further hinting that activities in the site are poised to ramp soon. This proposal, based on a response from PG&E that was recently shared online, was approved. 

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Based on these filings and job listings, it is evident that Tesla’s pilot battery cell manufacturing line has been ramping, or at least is poised to ramp, its operations. This is particularly impressive, considering that the Kato Road facility, which reportedly hosts the company’s skunkworks lab, is a fairly small site, comprising of two buildings that cover 184,880 sq. ft. combined. This means that even in this relatively small location, Tesla has been able to create a pilot line for a new breed of batteries that can change the EV game. This is quite a significant accomplishment, considering that previous battery lines are known to consume a lot of space. 

Tesla’s Gigafactory Nevada facility is the perfect example of this. Giga Nevada primarily produces battery cells, and it is poised to be one of the largest buildings in the world by footprint once it’s complete. If Tesla’s pilot battery cell production line in Kato Road is indeed fully functional and ramped, then one can only imagine how much more batteries facilities like Gigafactory Nevada can produce with the company’s next-generation technology. 

Tesla’s proposal for an expansion of its Kato Road facility could be accessed below.

Tesla Kato Road Update by Simon Alvarez on Scribd

H/T JPR007

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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SpaceX posts Starship booster feat that’s so nutty, it doesn’t even look real

The Super Heavy booster’s feat was so impressive that the whole maneuver almost looked like it was AI-generated.

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Credit: SpaceX/X

SpaceX has shared a video of a remarkable feat achieved by Starship’s Super Heavy booster during its 11th flight test.

The Super Heavy booster’s feat was so impressive that the whole maneuver, which was captured on video, almost looked like it was AI-generated.

Super Heavy’s picture perfect hover

As could be seen in the video shared by SpaceX, Starship’s Super Heavy booster, which is nearly 400 feet tall, smoothly returned to Earth and hovered above the Gulf of America for a few seconds before it went for its soft water landing. The booster’s picture-perfect maneuver before splashing down all but capped a near-flawless mission for Starship, which is about to enter its V3 era with Flight 12.

The booster’s balance and stability were so perfect that some users on X joked that the whole thing looked AI-generated. Considering the size of Super Heavy, as well as the fact that the booster was returning from space, the hovering display all but showed that SpaceX is dead serious about keeping its dominant lead in the spaceflight sector.

Starship V2’s curtain call

As noted in a Space.com report, Flight Test 11 achieved every major goal SpaceX had set for the mission, including deploying Starlink mass simulators, relighting Raptor engines in space, and executing a stable reentry for both the Starship Upper Stage and the Super Heavy booster. The feat also marked the second time a Super Heavy booster has been reflown, a milestone in SpaceX’s quest to make the entire Starship system fully reusable.

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Starship’s V2 vehicle will now give way to the upgraded Starship V3, which is designed for faster turnaround and higher payload capacity. The Starship program is expected to pursue even more aggressive targets in the coming months as well, with Elon Musk stating on social media platform X that SpaceX will attempt a tower catch for Starship Upper Stage as early as spring 2026.

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After moving Tesla to Texas, Elon Musk is back in the Bay Area with Neuralink expansion

The news marks a noticeable step in Musk’s expanding presence in the Bay Area, despite the move of his biggest companies, Tesla and SpaceX, to Texas.

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Neuralink-Demo-Elon-Musk
Credit: Steve Jurvetson/Twitter

Recent reports have indicated that Elon Musk’s brain-implant startup, Neuralink, has leased a five-story, 144,000-square-foot building in South San Francisco. At the same time, Musk’s artificial intelligence startup xAI is reportedly also looking around for a Bay Area office. 

The news marks a noticeable step in Musk’s expanding presence in the Bay Area, despite the move of his biggest companies, Tesla and SpaceX, to Texas.

Neuralink’s Bay Area expansion

As noted in a report from the San Francisco Business Times, the property that Neuralink has leased is located at 499 Forbes Boulevard, and it was built by Aralon Properties before it was leased to cancer test developer InterVenn Biosciences. The site, however, had remained vacant since 2023 after InterVenn canceled its 10-year lease.

xAI, Musk’s artificial intelligence startup, is reportedly scouting for an even larger Bay Area office as well, as noted in a report from the San Francisco Chronicle. Combined, the two ventures could secure nearly 400,000 square feet of local workspace, a move seen as a symbolic return of sorts for Musk-led innovation to Silicon Valley.

Neuralink’s momentum

Founded in 2016, Neuralink develops brain-computer interfaces intended to help paralyzed patients control digital devices through thought. The company received U.S. regulatory approval in 2023 to begin human trials, with its first patient, quadriplegic Noland Arbaugh, making headlines for his stunning ability to control a computer cursor and play games using only his mind. Since receiving his implant, Arbaugh has stated that he now browses the web, plays video games like Mario Kart, studies neuroscience, and operates his smart home without lifting a finger. 

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Nauralink is only just getting started, with Elon Musk noting on X that the company is busy preparing its next product, Blindsight, for human trials. As per Musk, Neuralink is “aiming to restore (limited) sight to the completely blind next year,” an aggressive target for a potentially life-changing device.

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Tesla Cybercab tests seem to be ramping up again

Elon Musk has stated that he expects the company to achieve a run rate of 2 million Cybercabs annually.

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Credit: @serobinsonjr/X

Tesla seems to be ramping the tests of its autonomous two-seater, the Cybercab, once more. This was hinted at in recent drone footage from both the Fremont Factory and Gigafactory Texas.

The fresh sightings of the Cybercab in the Fremont Factory and Giga Texas have renewed conversations about the vehicle potentially being built with manual controls today. 

Fresh Cybercab tests

As noted by longtime drone operator Joe Tegtmeyer on social media platform X, he recently spotted a Cybercab driving on Giga Texas’ South River Road to the West side. Interestingly enough, the longtime Giga Texas watcher noted that this was the first Cybercab that he had seen conducting road tests in a while.

Over in the Fremont Factory, another Cybercab was spotted driving around the facility’s testing area. Similar to the Cybercab in the Giga Texas sighting, the vehicle that was spotted in the Fremont Factory seemed to be manually driven, at least based on the way it was being steered. This behavior has incited speculations among Tesla watchers that current Cybercab test units have manual controls, unlike their production version, which would have no steering wheel or pedals. 

Cybercab production preparation

The sightings of Cybercabs around the Fremont Factory and Giga Texas bode well for the vehicle’s development and impending production. It does, if any, complement reports that Tesla has been busy setting up production equipment for Giga Texas’ Cybercab production line. At the same time, drone footage around the Giga Texas complex has also revealed that Tesla is stockpiling some Cybercab castings, a likely sign that initial test production of the vehicle might soon begin.

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The Cybercab is expected to be Tesla’s highest volume vehicle, with CEO Elon Musk stating that he expects the company to achieve a run rate of 2 million Cybercabs annually. He also mentioned that the Cybercab will be easy to produce thanks to its Unboxed manufacturing process, so much so that its production would resemble a high-speed consumer electronics line instead of an automotive assembly line.

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