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Tesla’s Elon Musk talks single cast design and its collision repair strategy

(Credit: Tesla)

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Elon Musk recently shared some details about Tesla’s collision repair strategy when the company rolls out its vehicles that are built using single-piece castings. The update provides a glimpse at Tesla’s emerging approach to vehicle maintenance and repair, an aspect of the electric car maker’s business that will likely be more notable as the company grows.

Considering that Tesla’s vehicles will be built with large, single-piece casts, members of the electric vehicle community have been inquiring about the company’s strategy for repairing damages from incidents like minor collisions. It would be quite challenging to replace vehicle parts, after all, if the electric cars are only comprised of a few, massive, casted pieces.

Inasmuch as this may be the case, Tesla appears to have come up with a rather novel solution for the potential challenges that will be brought about by single-piece casts. According to Musk, the crash absorption rails of vehicles like the Made-in-Germany Model Y could simply be “cut off & replaced with a bolted part for collision repair.”

Considering that Teslas are already challenging and costly to repair today, it would be quite interesting to see if the company’s use of bolt-on parts would make repairs cheaper or more expensive.

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Apart from his updates about Tesla’s collision repair strategy, the Tesla CEO also provided some details about the electric car maker’s structural battery packs, which are expected to be utilized for upcoming vehicles like the Model S Plaid, Cybertruck, and the Made-in-Germany Model Y. According to Musk, structural battery packs would make Tesla’s vehicles safer, as they provide better torsional rigidity and an improved polar moment of inertia.

“Battery pack will be a bonded structure with cells providing shear transfer between steel upper & lower face sheets, eliminating most of the center body parts while providing better torsional rigidity and improved polar moment of inertia. This is a major breakthrough,” Musk noted.

Interestingly enough, this detail was actually explained previously by automotive teardown expert Sandy Munro, who noted that a structural battery would make Teslas safer and less prone to untoward incidents like fires. Musk, for his part, appears to have validated Munro’s insights recently, stating on Twitter that the veteran “knows engineering.”

Some of Sandy Munro’s insights about Tesla’s structural battery pack could be viewed below.

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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 highlights one of Tesla FSD Supervised’s most underrated features

In his post on X, Musk wrote, “Tesla self-driving now recognizes hand signals.”

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Credit: Tesla

Tesla’s Full Self-Driving (Supervised) is able to recognize and respond to hand signals, as highlighted recently by CEO Elon Musk.

In his post on X, Musk wrote, “Tesla self-driving now recognizes hand signals.”

Musk shared the update in a quote reply to a video posted by Tesla Europe, which showed a vehicle operating with Full Self-Driving (Supervised) navigating a tight lane in the Netherlands while responding to hand gestures from a person directing traffic.

Hand signal recognition is an important capability for advanced driver-assistance and autonomous systems. In real-world driving, pedestrians, construction workers, parking attendants, and other drivers frequently use hand gestures to direct traffic, yield right of way, or indicate when it is safe to proceed. For a self-driving system operating in mixed environments, interpreting these non-verbal cues is critical.

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Musk’s post comes as Tesla owners have surpassed 8 billion cumulative miles driven with FSD (Supervised) engaged. “Tesla owners have now driven >8 billion miles on FSD Supervised,” the company wrote in a post on X.

Annual FSD (Supervised) miles have increased sharply over the past five years. Roughly 6 million miles were logged in 2021, followed by 80 million in 2022, 670 million in 2023, 2.25 billion in 2024, and 4.25 billion in 2025. 

In the first 50 days of 2026 alone, Tesla owners logged another 1 billion miles. At the current pace, the fleet is trending toward approximately 10 billion FSD (Supervised) miles this year.

Tesla’s latest North America safety data, covering all road types over a 12-month period, also indicates that vehicles operating with FSD (Supervised) were recorded one major collision every 5,300,676 miles. By comparison, the U.S. average during the same period was one major collision every 660,164 miles.

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Tesla hiring for Commercial Charging role hints at Semi push in Europe

The job opening was highlighted by David Forer, Senior Project Developer for Charging at Tesla, on LinkedIn.

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Credit: @HinrichsZane/X

Tesla appears to be expanding its Commercial Charging efforts in Central Europe. The job opening was highlighted by David Forer, Senior Project Developer for Charging at Tesla, on LinkedIn.

In a post on LinkedIn, Forer stated that Tesla is looking for a “high-energy executer to own Commercial Charging Sales in Central Europe.” He added that the role will involve closing commercial deals across Tesla’s “entire product range (Supercharging & Megacharging).”

The job listing specifies that the hire will lead the sale of Tesla’s high-power charging products, including Supercharger and Heavy Duty Charging, to major partners such as charge point operators, real estate owners, and retail companies. The role requires fluency in German and English and is based onsite in Munich.

Tesla already operates more than 75,000 Superchargers globally, though the Semi’s Megacharger network is still in its early stages. The inclusion of Heavy Duty Charging in the job description is notable, then, as it aligns with Tesla’s Megacharger infrastructure, which is designed to support the Tesla Semi.

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Tesla CEO Elon Musk recently confirmed that the Tesla Semi is moving into high-volume production this 2026. In a post on X, Musk noted that “Tesla Semi starts high volume production this year.”

Aerial footage of the Tesla Semi Factory near Giga Nevada also shows that the facility looks nearly complete, with work now underway inside the facility. 

Tesla has also refreshed the Semi lineup on its official website, listing two variants: Standard and Long Range. The Standard trim offers up to 325 miles of range with an energy consumption rating of 1.7 kWh per mile, while the Long Range version provides up to 500 miles. 

Both variants support fast charging and can recover up to 60% of range in 30 minutes using compatible infrastructure such as the Megacharger Network.

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The presence of Heavy Duty Charging in a Central Europe-focused sales role could indicate that Tesla is preparing charging infrastructure ahead of wider Semi deployment in the region. While Tesla has not formally announced a European launch timeline for the Semi, the vehicle, particularly its range, makes it an ideal fit for the area.

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Tesla Full Self-Driving set to get an awesome new feature, Elon Musk says

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Credit: Teslarati

Tesla Full Self-Driving is set to get an awesome new feature in the near future, CEO Elon Musk confirmed on X.

Full Self-Driving is the company’s semi-autonomous driving program, which is among the best available to the general public. It still relies on the driver to ultimately remain in control and pay attention, but it truly does make traveling less stressful and easier.

However, Tesla still continuously refines the software through Over-the-Air updates, which are meant to resolve shortcomings in the performance of the FSD suite. Generally, Tesla does a great job of this, but some updates are definitely regressions, at least with some of the features.

Tesla Cybertruck owner credits FSD for saving life after freeway medical emergency

Tesla and Musk are always trying to improve the suite’s performance by fixing features that are presently available, but they also try to add new things that would be beneficial to owners. One of those things, which is coming soon, is giving the driver the ability to prompt FSD with voice demands.

For example, asking the car to park close to the front door of your destination, or further away in an empty portion of the parking lot, would be an extremely beneficial feature. Adjusting navigation is possible through Grok integration, but it is not always effective.

Musk confirmed that voice prompts for FSD would be possible:

Tesla Full Self-Driving is a really great thing, but it definitely has its shortcomings. Navigation is among the biggest complaints that owners have, and it is easily my biggest frustration with using it. Some of the routes it chooses to take are truly mind-boggling.

Another thing it has had issues with is being situated in the correct lane at confusing intersections or even managing to properly navigate through local traffic signs. For example, in Pennsylvania, there are a lot of stop signs with “Except Right Turn” signs directly under.

This gives those turning right at a stop sign the opportunity to travel through it. FSD has had issues with this on several occasions.

Parking preferences would be highly beneficial and something that could be resolved with this voice prompt program. Grocery stores are full of carts not taken back by customers, and many people choose to park far away. Advising FSD of this preference would be a great advantage to owners.

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