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

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.
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
News
Tesla MultiPass in Europe expands, allowing ease of access to non-Tesla chargers
The Tesla MultiPass program in Europe is expanding to new countries. The program was launched earlier this year to assist Tesla owners in having an easier charging experience at non-Tesla EV chargers.
In September, Tesla launched the MultiPass program to owners in the Netherlands, which aimed to enable charging for Tesla owners at third-party stations using the app or keycard. It was developed to avoid having to use multiple apps for each charging manufacturer.
Tesla launches MultiPass to simplify charging at non-Tesla stations
Both access and payment would be performed through the Tesla app, streamlining the entire process.
Today, Tesla expanded the program to Sweden, Germany, the United Kingdom, France, and Belgium, building on its initial rollout and partnering with companies like Fastned to improve EV roaming coverage across the continent.
MultiPass is expanding in Europe. Your Tesla App and your Tesla keycard can start charging at third-party chargers in these countries.
We’re grateful to customers flagging any issues in the Tesla App. Payment success rate and coverage will continuously improve. https://t.co/1sr0OgdwLI
— Max (@MdeZegher) November 5, 2025
The program is still in its early stages, and it appears to have some issues, which were highlighted by owners.
Some state that the different designs between chargers can create a bit of a hassle, especially as some do not properly display charging rates and inconsistent pricing displays.
Additionally, Tesla’s Trip Planner and other route planner integrations are not as descriptive as they should be, so some owners suggested reliability and visibility improvements.
Tesla partnered with Electrify America, Rivian’s Adventure Network, and other networks to expand charging availability and make options more readily available.
Tesla’s Supercharger presence in Europe has expanded quite a bit over the past few years, but EVs are much more prevalent there than they are here in the U.S. The company has done a great job of growing the Supercharger presence this year, and there are currently over 11,000 stalls on the continent.
This year, Tesla added 200 total stations and roughly 1,250 total stalls, a 16 percent increase from last year. Europe also has a high concentration of V4 Superchargers, as nearly 42 percent of the stalls on the continent are V4, giving higher charging rates of up to 500 kW.
Cybertruck
Tesla announces delivery timeline for Cybertruck in new market
“Coming soon! Estimated deliveries in Q1 for UAE.”
Tesla announced its delivery timeline for the Cybertruck as it heads to a new market.
Tesla Cybertruck deliveries started in the United States and Canada back in late 2023. However, the company has been looking to expand the all-electric pickup to new markets, including the Middle East, for which it opened up orders for earlier this year.
Initially, Tesla planned to launch deliveries late this year, but there has been a slight adjustment to the timeline, and the company now anticipates the pickup to make its way to the first adopters in the United Arab Emirates in Q1 2026.
This was confirmed by the Tesla Cybertruck program’s lead engineer, Wes Morrill:
Coming soon! Estimated deliveries in Q1 for UAE
— Wes (@wmorrill3) November 2, 2025
Tesla first opened orders for the Cybertruck in the Middle East in mid-September of this year. It will be priced at AED 404,900 for the Dual Motor All-Wheel-Drive ($110,254) and AED 454,900 ($123,869) for the Cyberbeast trim.
The Cybertruck has been a highly anticipated vehicle in many parts of the world, but its ability to be sold in various regions is what is truly causing delays in the company’s efforts to bring the electric pickup worldwide.
Tesla confirms Cybertruck will make its way out of North America this year
In Europe, various agencies have challenged the design of the Cybertruck, arguing that it is unsafe for pedestrians due to its sharp edges and “boxy” design.
Agencies in the EU have said the vehicle’s “blade-like” protrusions are a violation of rules that ban sharp exterior edges that could cause severe injuries.
In Asia, Tesla will likely have to develop a smaller, more compact version of the vehicle as it does not align with local standards for urban environments. However, Tesla filed for energy consumption approval for the Cybertruck in December 2024, but there has been no real update on the status of this particular inquiry.
Overall, these issues highlight a real bottleneck in futuristic vehicle designs and the out-of-date regulations that inhibit the vehicle from becoming more widely available. Of course, Tesla has teased some other designs, including a more traditional pickup or even a compact Cybertruck build, but the company is not one to shy away from its commitments.
Nevertheless, the Cybertruck will appear in the Middle East for the first time in 2026.
Elon Musk
Tesla teases new AI5 chip that will revolutionize self-driving
Elon Musk revealed new information on Tesla’s AI5, previously known as Hardware 5, chip, for self-driving, which will be manufactured by both Samsung and TSMC.
The AI5 chip is Tesla’s next-generation hardware chip for its self-driving program, Optimus humanoid robots, and other AI-driven features in both vehicles and other applications. It will be the successor to the current AI4, previously known as Hardware 4, which is currently utilized in Tesla’s newest vehicles.
Elon Musk reveals Tesla’s HW5 release date, and that it won’t be called HW5
AI5 is specially optimized for Tesla use, as it will work alongside the company’s Neural Networks to focus on real-time inference to make safe and logical decisions during operation. It was first teased by Tesla in mid-2024 as Musk called it “an amazing design” and “an immense jump” from the current AI4 chip.
It will be roughly 4o times faster, have 8 times the raw compute, 9 times the memory capacity, 5 times the memory bandwidth, and 3 times the efficiency per watt.
It will be manufactured by both TSMC and Samsung at their Arizona and Texas fab locations, respectively.
Here’s what Musk revealed about the chip yesterday:
Different Versions
Samsung and TSMC will make slightly different versions of the AI5 chip, “simply because they translate designs to physical form differently.” However, Musk said the goal is that its AI software would work identically.
This was a real concern for some who are familiar with chip manufacturing, as Apple’s A9 “Chipgate” saga seemed to be echoing through Tesla.
Back in 2015, it was found that Apple’s A9 chips had different performances based on who manufactured them. TSMC and Samsung were both building the chips, but it was found that Samsung’s chips had shorter battery life than TSMC-fabricated versions.
Apple concluded that the variance was about 2-3 percent. However, Tesla will look to avoid this altogether.
Release and Implementation into Vehicles
Musk said that some samples will be available next year, and “maybe a small number of units” would equip the chip as well. However, high-volume production is only possible in 2027.
This means, based on Tesla’s own timeline for Cybercab production in Q2 2026, early iterations of the vehicle would rely on AI4. Many believe AI4 can be utilized for solved self-driving, but the power of subsequent versions, including AI5 and beyond, will be more capable.
AI6 and Beyond
AI6 will utilize the same fabs as AI5, but there would be a theoretical boost in performance by two times with this version.
AI6 could enter volume production by mid-2028. However, AI7, which Musk only briefly mentioned, “will need different fabs, as it is more adventurous.”
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