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Volvo to adopt “Tesla style” megacasts for its next-gen electric vehicles

Credit: Idea Group/YouTube

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The use of Giga Presses may be considered futile and ill-conceived by Tesla skeptics, but it appears that some veteran automakers are currently preparing to adopt the technology for their next generation electric vehicles. First up seems to be Volvo, which recently noted that its Torslanda factory in Sweden, one of the company’s oldest and largest plants, would be shifting to the use of megacasts within the coming years. 

Similar to Tesla, which practically pioneered the use of megacasts by using them for the Model Y, Volvo would be using the massive components for its next-generation electric vehicles. In a statement to Automotive News Europe, Volvo Solution Architect Vehicle Platform Mikael Fermer remarked that the use of megacasts is one of the company’s biggest technological shifts. “This is the biggest technology shift since we switched from wood to steel (for car bodies),” Fermer said. 

Volvo’s Torslanda car plant (Credit: Volvo Cars)

The Torslanda factory is one of Volvo’s most historical sites, having been opened in April 1964. The facility is expected to receive numerous changes during its transition into an electric vehicle factory. A battery assembly plant would be added to the site, which would allow the automaker to integrate battery cells and modules to the floor structures of its upcoming EVs. 

Volvo’s head of engineering and operations Javier Varela noted that the shift to the use of megacasts could result in 75% time savings compared with how large aluminum body components are traditionally put together today. “You avoid the stamping and welding processes and replace them with a megacasting process that is a one-shot injection followed by some tweaks after the injection,” Varela said. 

Varela also noted that ultimately, the use of megacasted parts should allow Volvo to enjoy some sustainability benefits. “All the aluminum that you are injecting is used. You don’t have any scrap like you do with stamping,” Varela added. 

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While exciting, the utilization of megacasts in Volvo’s Torslanda plant is expected to start around 2025. By this time, the factory would likely also be ready to start the full production of the company’s next-generation EVs. Today, the Torslanda plant produces vehicles like the Volvo XC90 and XC60 SUVs, as well as the V90 station wagon. 

Credit: Tesla

Interestingly enough, it is not just Volvo that is looking to adopt megacasts in their future vehicle production. Other automakers such as German luxury car maker Mercedes-Benz is reportedly looking to utilize single-piece casts as well. Mercedes-Benz is reportedly looking to utilize megacasts to form the rear of its EQXX concept, which made its debut in Las Vegas last month during CES 2022. 

Volvo is yet to announce if it is also purchasing Giga Presses from the IDRA Group, the company currently producing Tesla’s machines. That being said, the automaker did state that it was speaking with leading machine manufacturers to help the company make the switch to megacasts at the Torslanda site. No final decisions have been made yet, however, according to a Volvo spokesperson.

Volvo is looking to make half of its global vehicle sales from battery-powered cars by 2025. By 2030, the company plans to be an electric-only carmaker. To help foster and accelerate this transition, Volvo has announced investments totaling over $4 billion over the past two years. 

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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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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Tesla Robotaxi service in Austin achieves monumental new accomplishment

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Credit: Tesla

Tesla Robotaxi services in Austin have been operating since last Summer, but Tesla has admittedly been delayed in its expansion of the geofence, fleet size, and other details in a bid to prioritize safety as new technology rolls out.

But those barriers are being broken with new guardrails being removed from the program.

Tesla has achieved a significant advancement in its autonomous ride-hailing program. As of May 4, the Robotaxi fleet in Austin, Texas, has begun operating unsupervised during evening hours for the first time. This expansion moves beyond previous limitations that restricted unsupervised service to daylight hours, typically ending in mid-afternoon.

The change brings Austin in line with operations in Dallas and Houston. Those cities have supported evening unsupervised runs since their initial launches in April, and both recently received additions of new unsupervised vehicles to their fleets. This coordinated progress across Texas strengthens Tesla’s regional presence and provides a broader testing ground for the technology.

This milestone carries substantial weight in the development of autonomous vehicles. Extending operations into low-light conditions meaningfully expands the Robotaxi’s operational design domain (ODD)—the specific environments and scenarios in which the system is approved to operate safely without human intervention.

Nighttime driving presents unique technical demands: diminished visibility, headlight glare from oncoming traffic, reduced contrast for identifying pedestrians and lane markings, and greater variability in camera sensor exposure.

Tesla Cybercab just rolled through Miami inside a glass box

Tesla’s pure vision approach, powered by neural networks trained on vast real-world datasets rather than lidar or pre-mapped routes, must handle these variables reliably. Demonstrating consistent unsupervised performance after sunset validates the robustness of the end-to-end AI stack and its ability to generalize across diverse lighting conditions.

Beyond technical validation, the expansion holds important operational and economic implications. Evening hours often coincide with peak urban demand for rides, including commutes, dining, and entertainment outings.

Enabling service during these periods increases daily vehicle utilization, allowing each Robotaxi to generate more revenue while gathering additional high-value training data. Higher utilization accelerates the virtuous cycle of data collection, model improvement, and further ODD growth.

Looking ahead, this step paves the way for more ambitious rollouts. Success in low-light environments positions Tesla to pursue near-24-hour operations, potentially integrating highways and expanding into varied weather patterns. Regulators worldwide frequently demand evidence of safe performance across day-night cycles before granting wider approvals.

Proven capability in Texas could expedite deployments in planned cities such as Phoenix, Miami, Orlando, Tampa, and Las Vegas during the first half of 2026.

Tesla confirms Robotaxi expansion plans with new cities and aggressive timeline

Moreover, scaling evening service supports Tesla’s long-term vision of a high-efficiency robotaxi network. Greater fleet productivity lowers the cost per mile, making autonomous mobility more accessible and competitive against traditional ride-hailing.

As the company iterates on software updates informed by nighttime data, reliability is expected to compound rapidly, unlocking denser urban coverage and longer-distance trips.

In summary, the introduction of an unsupervised evening Robotaxi service in Austin represents more than an incremental schedule adjustment. It signals a critical maturation of the underlying technology and sets the foundation for broader geographic and temporal expansion.

With Texas operations gaining momentum, Tesla is steadily advancing toward transforming urban transportation at scale.

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Tesla Cybercab just rolled through Miami inside a glass box

Tesla paraded a Cybercab in a glass display at Miami’s F1 Grand Prix event this week.

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Tesla Cybercab at the Miami F1 Fan Fest 2026: Credit: TESLARATI

Tesla set up an “Autonomy Pop-Up” at Lummus Park in Miami Beach from April 29 through May 3, 2026, embedded within the official F1 Miami Grand Prix Fan Fest.  The centerpiece was a Cybertruck towing the Cybercab inside a glass display case marked “Future is Autonomous,” rolling through the beachfront crowd.

Miami is on Tesla’s confirmed list of cities for robotaxi expansion in the first half of 2026, making the promotion a strategic promotion that lays groundwork in a target market.

This was not Tesla’s first time using Miami as a showcase city. In December 2025, Tesla hosted “The Future of Autonomy Visualized” at its Miami Design District showroom, coinciding with Art Basel Miami Beach. That event featured the Cybercab prototype and Optimus robots interacting with attendees. The F1 pop-up this week marks Tesla’s return to Miami and follows a pattern Tesla has been running since early 2026. Just two weeks before Miami, Tesla stationed Optimus at the Tesla Boston Boylston Street showroom on April 19 and 20, directly on the final stretch of the Boston Marathon, letting tens of thousands of runners and spectators meet the robot for free, generating massive earned media at zero advertising cost.

Tesla is sending its humanoid Optimus robot to the Boston Marathon

Tesla has confirmed plans to expand its robotaxi service to seven cities in the first half of 2026, including Dallas, Houston, Phoenix, Miami, Orlando, Tampa, and Las Vegas, building on the unsupervised service already running in Austin. Musk has said he expects robotaxis to cover between a quarter and half of the United States by end of year. On the production side, Musk told shareholders that the Cybercab manufacturing process could eventually produce up to 5 million vehicles per year, targeting a cycle time of one unit every ten seconds. Scaling robotaxis to 10 million operational units over the next ten years is a key condition of his compensation package, alongside selling 20 million passenger vehicles.

As for the Cybercab’s price, Musk has said buyers will be able to purchase one for under $30,000, with an average operating cost around $0.20 per mile. Whether those numbers hold through full production remains to be seen.

Cybercab at F1 Fan Fest in Miami
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Tesla Semi gets new product launch as mass manufacturing hits Plaid Mode

While the 1.2 MW Megacharger handles quick 30-minute en-route boosts, the Basecharger serves as a reliable overnight solution for longer dwell times at warehouses, distribution centers, fleet yards, and even, potentially, homes.

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Credit: Tesla

The Tesla Semi is getting a new production launch as mass manufacturing on the all-electric truck is gearing up to hit Plaid Mode.

Tesla has introduced a game-changing addition to its commercial charging lineup with the new 125 kW Basecharger for Semi. Launched this week as part of the new “Semi Charging for Business” program, this compact unit is purpose-built for depot and overnight charging of Tesla Semi trucks.

While the 1.2 MW Megacharger handles quick 30-minute en-route boosts, the Basecharger serves as a reliable overnight solution for longer dwell times at warehouses, distribution centers, fleet yards, and even, potentially, homes.

Delivering up to 60 percent of the Semi’s range in roughly four hours, perfect for overnight top-ups during mandated driver rest periods or while trucks are loaded or unloaded. Its fully integrated design eliminates the need for bulky separate AC-to-DC cabinets.

Tesla engineers tucked one of the power modules from a V4 Supercharger Cabinet directly inside the sleek post, resulting in a compact footprint. It also features a six-meter cable for layout flexibility. This is one thing that must have been learned through the V4 Supercharger rollout.

Installation and operating costs drop dramatically thanks to daisy-chaining. Up to three Basechargers can share a single 125 kVA breaker, slashing electrical infrastructure requirements. The unit outputs 150 amps continuous across an 180–1,000 VDC range, matching the Semi’s high-voltage architecture while supporting the MCS 3.2 standard.

Tesla Semi sends clear message to Diesel rivals with latest move

Priced from $40,000 for a minimum order of two units, the Basecharger is far more affordable than the $188,000 Megacharger setup for two posts. Deliveries begin in early 2027. Buyers also receive Tesla’s full network-level software, remote monitoring, maintenance, and a guaranteed 97 percent or higher uptime—critical for fleet reliability.

This launch arrives as Tesla accelerates high-volume Semi production at its Nevada factory, targeting 50,000 units annually. By pairing affordable depot charging with ultra-fast highway options, Tesla removes one of the biggest obstacles to electrifying Class 8 trucking: infrastructure cost and complexity.

Fleet operators stand to gain lower electricity rates during off-peak hours, dramatically reduced maintenance compared to diesel, and quieter yards at night. The Basecharger isn’t just another charger—it’s the practical bridge that makes large-scale electric semi adoption economically viable.

With the Basecharger handling “home” duties and Megachargers powering the road, Tesla is delivering a complete ecosystem that could finally tip the scales toward zero-emission freight. For trucking companies ready to go electric, the future just got a whole lot more charger-friendly.

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