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USPS announces plans to order 5,000 EVs & achieve 70% fleet electrification

(Credit: USPS)

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On Sunday, February 6, the United States Postal Service (USPS) announced plans to submit an initial order for 5,000 electric delivery vans. The announcement was made to show that the USPS is committed to the fiscally responsible rollout of electric-powered vehicles for America’s largest federal fleet. 

The Postal Service also announced plans to achieve 70% fleet electrification within the decade. Postmaster General and USPS Chief Executive Officer Louis DeJoy stated that the Postal Service would be open to increasing its number of electric vehicle orders “should additional funding become available.” The Postmaster tried to elaborate on the USPS’ financial challenges of committing to operating a cleaner Postal vehicle fleet. 

“Moreover, comparisons of the Postal Service to private sector multi-national corporations that report yearly profits in the billions of dollars, and that are not required to go to 161 million delivery addresses in all climates and topographies six days per week, are not relevant in view of our perilous financial condition and universal service mission,” DeJoy clarified. 

“We will be resolute in making decisions that are grounded in our financial situation and what we can realistically achieve while pushing hard to take delivery of safer, cleaner vehicles by next year. Given our large fiscal deficits and significant financial challenges, Congress is well aware of the additional resources that would be required if Congress would prefer the Postal Service to accelerate the electrification of our delivery vehicle fleet as a matter of public policy,” he explained.

The agency’s recent announcement stated clearly that the Postal Service generally does not receive tax dollars for operating expenses. It relies on postage sales, products, and services to fund its operations. 

USPS’ New Delivery Van

On February 23, 2021, the USPS announced a 10-year contract with Oshkosh, WI, to manufacture a new generation of U.S.-built postal delivery vehicles. At the time, the agency stated that the new delivery van from Oshkosh would “drive the most dramatic modernization of the USPS fleet in three decades.” 

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As per the contract’s initial $482 million investment, Oshkosh was supposed to finalize the production design of the agency’s Next Generation Delivery Vehicle (NGDV). The agreement also stated that Oshkosh would assemble 50,000 to 165,000 NGDVs for the USPS. Last month, the NGDV’s design was showcased during CES 2022 in Las Vegas. 

(Credit: USPS)

Biden Administration Pushes Back on the NGDV

Last week, members of President Joe Biden’s administration sent letters to the Postal Service, urging the agency to reconsider its plans to buy mostly gas-powered vehicles to upgrade its fleet. The agency’s plans to spend up to $11.3 billion on as many as 165,000 new gas-powered delivery vans in the next decade could have major implications for President Biden’s goal to convert federal cars and trucks to clean energy. The Postal Service fleet makes up a third of the US government’s fleet. 

Accoring to the USPS, the NGDV is larger and has a more fuel-efficient internal combustion engine compared to the currently deployed Long Life Vehicle (LLV). The NGDV’s fuel economy is 14.7 MPG when air conditioning isn’t running compared to the LLV’s fuel economy of 8.4 MPG, which does not have an AC system. The new Postal delivery van will be fitted with safety features like 360 degree cameras, front and rear braking, and a driver airbag.

However, the USPS also designed the NGDV to accommodate advancements in technology in its 20-year life. The Postal Service declared that the NGDV has a platform that could be equipped with either an internal combustion engine or battery electric drive train. 

The agency stated that its cost estimates—presumably referring to costs related to the NGDV—included the price of charging infrastructure. It plans to charge delivery vans in bulk at USPS facilities. The Postal Service is analyzing state and local electrical grid capacity to determine any potential upgrades it needs to implement at the grid-level. 

Below is a letter from the White House to the USPS.

USPS Letter 2022 by Maria Merano on Scribd

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Maria--aka "M"-- is an experienced writer and book editor. She's written about several topics including health, tech, and politics. As a book editor, she's worked with authors who write Sci-Fi, Romance, and Dark Fantasy. M loves hearing from TESLARATI readers. If you have any tips or article ideas, contact her at maria@teslarati.com or via X, @Writer_01001101.

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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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