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Tesla ‘Roadrunner’ battery cell facility begins to take shape at Fremont

(Credit: @sensarpensar/Twitter)

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Recent images taken of Tesla’s battery production facility in Kato Road near the Fremont Factory suggest that the expansion of the site is already underway. According to a Tesla owner-enthusiast who recently visited the location, the site of Tesla’s Project “Roadrunner” is now abuzz with activity.

Tesla community member @sensarpensar opted to visit Tesla’s Fremont delivery center as the company was undergoing its final end of quarter sprint. During his visit, the Tesla owner remarked that there were numerous people taking delivery of their vehicles. Tesla Model Y units that were being handed over to customers also had VINs in the 24k range. This suggests that the company’s production of the all-electric crossover is hitting its stride.

Following his visit to the Tesla’s delivery site at Fremont, the EV enthusiast headed over to the company’s Kato Road facility, where the company’s pilot battery production line is reportedly being ramped. Documents filed to the City of Fremont indicate that Tesla intends to expand the facility by adding another floor to the existing building, and this is exactly what was happening during the Tesla owner’s visit.

In a follow up tweet, @sensarpensar noted that a massive crane has been set up on the site, and there was a significant number of construction workers in the location. Looking at the images, it appears that some of the steel framework of the Kato Road facility’s additional floor has been set up as well. This is quite encouraging to see, as it highlights Tesla’s intention to ramp the operations of its pilot battery cell production line.

According to Tesla’s filings with the City of Fremont, the expanded facility will be housing 45 research and development employees and up to 425 manufacturing workers that are spread through several shifts from Monday to Friday. Multiple job openings related to cell manufacturing activities have been posted by Tesla in recent months as well, including listings for Cell Engineers, Production Process Engineers, and Controls Engineers, all of which were based in Fremont, California.

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What is rather interesting is the fact that the Kato Road facility, even with its expansion, is a conservatively-sized location. The facility is comprised of two buildings that cover 184,880 sq. ft. combined. This suggests that Tesla has been able to set up a legitimate pilot battery cell production line in a relatively small location, which is quite impressive in its own right.

Initial reports about Project Roadrunner were posted as early as June 2019, when CNBC reported that Tesla’s Kato Road facility was being used as a “skunkworks lab” to design and produce battery cells and battery manufacturing equipment. These batteries were reportedly next-generation lithium-ion cells, which are expected to be the company’s much anticipated million mile battery.

Below are Tesla’s filings for the expansion of its Kato Road facility.

Tesla Kato Road Update by Simon Alvarez on Scribd

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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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Elon Musk

SpaceX is preparing to launch Starship V2 one final time

The mission will test reentry dynamics, new landing burn configurations, and heat-shield upgrades.

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Credit: SpaceX/X

SpaceX is preparing to launch its final Starship V2 rocket on October 13, 2025. The launch closes the curtain on Starship V2 and marks the start of the ambitious spacecraft’s V3 era. 

Liftoff for Flight 11 is scheduled for 7:15 p.m. ET from Starbase in South Texas, with a 75-minute launch window. The mission will test reentry dynamics, new landing burn configurations, and heat-shield upgrades ahead of the transition to the next-generation Starship V3.

Starship V3 and beyond

Elon Musk confirmed on X that Starship V3 is already in production and could be “built & tested” and perhaps even flown before the end of 2025. The new version is expected to feature major performance and scale improvements, with Musk stating that Starship V3, provided that things go well, might be capable of reaching Mars, though V4 is more likely to perform a full-scale mission to the red planet. 

“Only one more V2 left to launch,” Musk wrote back in August following Starship’s successful Flight 10 mission. In another post, Musk stated that “Starship V3 is a massive upgrade from the current V2 and should be through production and testing by end of year, with heavy flight activity next year.”

Starship V2’s final mission

Flight 11 is designed to push the limits of Starship V2. SpaceX engineers have intentionally removed heat-shield tiles in vulnerable areas to analyze how the vehicle handles atmospheric reentry under stress, as noted in a Space.com report. The test will also refine subsonic guidance algorithms and new landing burn sequences for the Super Heavy booster that would be used for Starship V3.

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“Super Heavy will ignite 13 engines at the start of the landing burn and then transition to a new configuration with five engines running for the divert phase. Previously done with three engines, the planned baseline for V3 Super Heavy will use five engines during the section of the burn responsible for fine-tuning the booster’s path, adding additional redundancy for spontaneous engine shutdowns. 

“The booster will then transition to its three center engines for the end of the landing burn, entering a full hover while still above the ocean surface, followed by shutdown and dropping into the Gulf of America,” SpaceX wrote in a post on its official website.

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Elon Musk

xAI’s new facility will save Memphis 5 billion gallons of water annually

The project was described as a long-needed solution for the region as it will be capable of recycling up to 13 million gallons of greywater daily.

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Credit: xAI Memphis/X

Elon Musk’s artificial intelligence startup, xAI, has officially broken ground on its $80 million wastewater treatment facility in Memphis, Tennessee. The project aims to reduce strain on the Memphis aquifer by 9% and repurpose 20% of wastewater from the nearby Memphis T.E. Maxson wastewater facility that would otherwise flow back into the Mississippi River.

A major step towards sustainability

City officials, including Councilman J. Ford Canale and Memphis Chamber of Commerce CEO and President Ted Townsend, joined xAI staff at the October 10 ceremony. The project was described as a long-needed solution for the region as it will have a treatment capacity of 13 million gallons daily, which would then be used for industrial cooling use xAI and the Tennessee Valley Authority (TVA). 

This means that the facility will help conserve 5 billion gallons of potable water annually, easing demand on Memphis’ primary water system. At these levels, xAI Memphis noted that its wastewater treatment facility will feature the largest ceramic membrane MBR in the world, using 13,000 membrane modules that collectively span over 900,000 square feet, roughly the size of 16 football fields. 

Construction permits have been secured for the pump station, while the main operations permit from the Tennessee Department of Environment and Conservation remains under review.

A privately funded push

The wastewater treatment facility represents a rare privately funded water reclamation initiative, with xAI covering construction costs, as noted in a Yahoo News report. The company filed preliminary plans through its affiliate CTC Property LLC in 2024, hinting at the startup’s long-term commitment to sustainable infrastructure around its growing Memphis operations. TVA CEO and President Don Moul shared his excitement for the project.

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“This is a big day for Memphis, Tennessee. This initiative not only reduces our need to purchase water from MLGW for our nearby Allen Combined Cycle Plant, but it also eases demand on the region’s potable water system. By recycling water for cooling purposes, we’re helping to preserve drinking water for the community and advancing a solution that benefits both the environment and the Greater Memphis area,” he said.

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Japan paves the way for Tesla Full Self-Driving domestic rollout

Tesla’s vehicles are allowed to be retrofitted with a software update that could enable the activation of self-driving features.

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Credit: Tesla AI/X

Japan seems to be taking some serious steps to pave the way for the domestic rollout of Tesla’s Full Self-Driving (FSD) system in the country. 

This was hinted at by a decision from the Ministry of Land, Infrastructure, Transport and Tourism Ministry.

FSD update

As noted in a report from Nikkei, Tesla’s artificial intelligence-powered vehicles are allowed to be retrofitted with a software update that could enable the activation of their self-driving features. These features would be rolled out through an over-the-air (OTA) software update for vehicles that have already been sold to consumers.

Previous reports have indicated that Tesla Japan has started the testing of FSD technology on public roads. At the time, reports indicated that Tesla Japan employees have been conducting the tests, and the company is planning to release its FSD software to consumers in the near future, at least pending compliance with safety standards and guidelines. 

New guidelines

In a comment on X, former Tesla Board Member Hiro Mizuno explained that the Ministry of Land, Infrastructure, Transport and Tourism Ministry’s decision is no small matter, as it could pave the way for the smooth rollout of features like FSD to Tesla consumers in Japan. 

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“The Ministry of Land, Infrastructure, Transport and Tourism’s decision to allow retrofitting of autonomous driving through software updates is significant. Currently, Tesla is the only manufacturer actively pursuing this, but I had thought that if actual autonomous driving were to begin, it would be impossible to keep up if the approval process had to be repeated for every software update. As a result, this decision will make it easier for all manufacturers to introduce autonomous driving in Japan,” he wrote in a post on X.

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