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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 launches solution to end Supercharger fights once and for all

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Credit: Tesla

Tesla is launching its solution to end Supercharger fights once and for all, eliminating any confusion on who is to charge next at a congested location.

Last year, a notable incident at a Tesla Supercharger led to a fight, and it all stemmed from a disagreement over who arrived at the location first.

Congestion at Tesla Superchargers is a pretty infrequent occurrence for most of us, but there are more congested and popular areas where wait times can be extensive. An unfortunate growing pain of EV ownership is the plain fact that chargers are not as available as gas pumps, and there are, at times, lines to charge.

This can cause tensions to flare and people to get entitled when visiting Superchargers. Nobody wants to spend hours at a Supercharger, but now, there will be no more confusion when there is a queue, and that’s thanks to Tesla’s new Virtual Queue for Superchargers.

Tesla is finally starting to build out the Virtual Supercharger Queue, according to Not a Tesla App, but it still relies on drivers to make it work.

When a driver is near a Supercharger that is full, a message will pop up on the Tesla App, using the driver’s location to determine their eligibility to join the virtual queue.

The app states:

“While the app is closed, Tesla uses your location to notify you of accurate wait times at Superchargers when you arrive.”

Another message within the app states:

“There is a waitlist to charge. Are you sure you want to start a charging session now?”

This sounds as if it will require drivers to act appropriately and only plug in when the app prompts them to do so, by letting them know it is their turn.

The app will notify the driver of their position in the queue, as well as how many vehicles are ahead of them.

Tesla launches first ‘true’ East Coast V4 Supercharger: here’s what that means

The company announced a while back that it would be working on a solution for this issue. Personally, I’ve only had to wait at a Supercharger for a charge on one occasion, and there was a line of between 3 and 10 cars during this singular occurrence.

There were no conflicts or arguments about who had arrived first, but there was some discussion between several drivers during my time there about who was to charge first. Throw a non-Tesla EV into the mix, one that can only charge at a pull-in spot, and that causes even more of a complication.

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Tesla offers awesome Free Supercharging incentive on an unexpected vehicle

In the past, Tesla has used Free Supercharging to incentivize the purchase of its expensive vehicles, like the Model S and Model X. However, those vehicles are leaving the company lineup, and Tesla saw a benefit from applying the incentive to another car.

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Credit: Tesla Charging | X

Tesla is offering an awesome new Free Supercharging incentive on a vehicle that is sort of unexpected.

In the past, Tesla has used Free Supercharging to incentivize the purchase of its expensive vehicles, like the Model S and Model X. However, those vehicles are leaving the company lineup, and Tesla saw a benefit from applying the incentive to another car.

Tesla North America has introduced a compelling new incentive aimed at boosting Model 3 sales. Starting with orders placed on or after April 24, buyers of the Model 3 Premium (Long Range) and Performance variants in the United States will receive one full year of complimentary Supercharging.

The offer applies exclusively to new vehicle orders and does not extend to existing owners or other trims like the base Rear-Wheel Drive model.

The announcement underscores Tesla’s continued dominance in EV charging infrastructure.

While the incentive provides 12 months of zero-cost access to the Supercharger network, Tesla also reiterated its pricing structure: all Tesla vehicles receive the lowest Supercharging rates.

Non-Tesla EVs, by contrast, pay approximately 40 percent more per kWh or must purchase a subscription to access the network at standard rates. This tiered approach highlights the strategic value of owning a Tesla, where seamless integration with the world’s largest and most reliable fast-charging network remains a key differentiator.

For prospective buyers, the savings can be substantial. Depending on driving habits, a typical Model 3 owner might log 12,000–15,000 miles annually.

With average Supercharging costs around $0.40–$0.50 per kWh, one year of free sessions could translate to $800–$1,200 in avoided expenses.

That effectively lowers the total cost of ownership and makes long-distance travel more affordable from day one. Early delivery customers have already noted similar past incentives, with one Cybertruck owner reporting over $2,400 saved in just six months under similar offers that Tesla has deployed in the past.

The timing of the offer appears strategic. Tesla faces growing competition from other automakers expanding their own charging networks and offering aggressive EV incentives.

By bundling free Supercharging rather than discounting the vehicle’s MSRP, Tesla preserves perceived value while directly addressing one of the biggest barriers for new EV adopters: charging costs and convenience.

The move also encourages higher-mileage use of the network, generating valuable real-world data for Tesla’s autonomous driving development.

Why Tesla would apply this incentive to the Model 3 is pretty interesting. It usually is a pretty good incentive to move units out the door, so there’s some speculation whether Tesla is planning to launch new upgrades to the mass-market sedan in the coming months, and the company wants to move what will be outdated units from its inventory.

However, there is also just the idea that Tesla could be attempting to stimulate some early quarter demand for the Model 3, especially as the Model Y continues to sell very well. Tesla’s loss of the $7,500 EV tax credit last year had an impact on sales, and Tesla might be testing some formidable options to see if it can add some demand once again.

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Tesla Cybercab gets crazy change as mass production begins

Tesla has officially kicked off mass production of its groundbreaking Cybercab robotaxi at Giga Texas, and the first units rolling off the line feature a striking transformation that’s turning heads across the EV community.

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Credit: TechOperator | X

Tesla Cybercab has evidently received a pretty crazy change from an aesthetic standpoint, as the company has made the decision to offer an additional finish on the vehicle as mass production is starting.

Tesla has officially kicked off mass production of its groundbreaking Cybercab robotaxi at Giga Texas, and the first units rolling off the line feature a striking transformation that’s turning heads across the EV community.

VIN Zero—the very first production Cybercab—showcases a vibrant champagne gold exterior with a high-gloss finish, a dramatic departure from the flat, matte-wrapped prototypes that debuted at the 2024 “We, Robot” event.

This glossy sheen is a pretty big pivot from what was initially shown by Tesla. The company has maintained a pretty flat tone in terms of anything related to custom colors or finishes.

A specialized clear coat or process delivers the deep, reflective gloss without conventional painting. The result is a premium, mirror-like shine, and it looks pretty good, and gives the compact two-seater a more luxurious and futuristic presence than the subdued matte prototypes.

Photos shared by Tesla community members reveal VIN Zero in a showroom-like setting at Giga Texas, highlighting refined panel gaps, large aero wheel covers, and the signature no-steering-wheel, no-pedals interior optimized for full autonomy.

The open frunk in some images offers a glimpse of practical storage, while the overall build quality appears more polished than that of test mules.

This glossy evolution aligns with Tesla’s broader production ramp. After the first unit in February 2026, the company has shifted to volume manufacturing, with dozens of units already spotted in outbound lots. CEO Elon Musk and the team aim for hundreds per week, paving the way for unsupervised FSD robotaxi networks that could slash ride costs to pennies per mile.

The Cybercab holds Tesla’s grand ambitions of operating a full-service ride-hailing service without any drivers in its grasp. Tesla has yet to solve autonomy, but is well on its way, and although its timelines are usually a bit off, improvements often come through the Over-the-Air updates to the Full Self-Driving suite.

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