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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. 

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.

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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.

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

Elon Musk follows Trump’s lead, says a SpaceX name change is coming

Elon Musk says SpaceXAI will become SpaceXSI, marking its second rebrand in under three months.

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Elon Musk wants to rename his artificial intelligence company again, less than three months after its last rebrand.

In a string of posts on X early Sunday morning, Musk wrote “No more AI,” followed by “SI” and “It’s better.” He then added, “SpaceX is a super intelligence company.” When a user asked whether SpaceXAI could become SpaceXSI, Musk replied, “Yes, we will make that change.”

The posts extend a terminology push that began at the White House last week. On September 29, President Donald Trump signed an executive order directing federal agencies to replace “artificial intelligence” and “AI” with “Super Intelligence” and “SI” on government websites, policy documents and press releases. The same day, Musk sat beside Trump as the heads of the largest AI companies signed a voluntary safety accord, as Teslarati reported. Speaking to reporters afterward, Musk caught himself mid sentence: “I think it is worth highlighting the positive benefits of A.I. … S.I., pardon me.”

Elon Musk and Trump are closer than ever, and Tesla could be the big winner

SpaceXSI would be the third name for the business since February. SpaceX acquired xAI on February 2 in a deal that valued the combined company at $1.25 trillion. In May, Musk said xAI would be dissolved as a separate company, and on July 6 the division adopted the SpaceXAI name and a new logo that placed the xAI letters inside the SpaceX identity.

Musk gave no timeline. He did not say whether SpaceXSI would be a legal name change or a branding update, whether the @SpaceXAI handle on X would change, or how the shift would apply to products like Grok. The company had not issued a formal announcement as of Sunday morning.

The change would reach well beyond a chatbot. SpaceXAI now houses Grok, the X platform, the Colossus training clusters in Memphis and the coding tool Cursor, which SpaceX acquired in August. It also runs the orbital compute effort SpaceX is building around Nvidia hardware, which Musk said during the company’s first earnings call would be exclusive to Nvidia.

It’s unclear if rivals like Anthropic, OpenAI, Google, Meta and Nvidia have plans to also rename their companies or products. OpenAI CEO Sam Altman has continued to say “AI” in public, while Nvidia CEO Jensen Huang has gone partway, describing data centers as “super intelligence factories.”

The rename would also line up SpaceX’s AI branding with the federal government’s language as Musk takes on a new advisory role at the Pentagon, where he is helping lead the Project Meridian study on the future of warfare.

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Starlink launches Communities Program for passive income through internet sharing

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(Credit: Starlink | X)

Starlink is launching a new beta path for ordinary property owners and local operators to turn a single Starlink kit into a small shared-access business for passive income.

Under the Starlink for Communities program, a host installs one dish and router setup in a location with nearby demand: an apartment complex, campground, rural crossroads, or event site. Neighbors or local users can buy short-term passes rather than full individual subscriptions, giving the Starlink provider a potential path to passive income.

Hour, day, and week passes cover one device. A month pass covers up to four. Starlink handles account creation, payments, access controls, and the satellite link itself. The host’s role is mainly placement, power, and basic upkeep, with earnings tied to each paid connection.

The model echoes the passive-income vision long attached to Tesla’s Robotaxi plans, and it seems like it’s something Musk has hinted toward in the past as he believes AI will make the need to work relatively optional. In both cases, the platform owns the hard parts of matching, billing, and network management, while an individual supplies a physical asset that sits idle much of the time.

A Starlink host’s dish can serve multiple nearby users without each household buying and installing its own terminal. A Tesla owner, under the stated Robotaxi concept, would leave a vehicle enrolled in the fleet during unused hours so the car generates rides while the owner is at work or asleep.

Both arrangements convert under-utilized hardware into a revenue stream. They also let the company scale coverage or capacity without owning every endpoint.

Differences are practical. A Starlink kit is a fixed, relatively low-cost terminal whose main constraint is local congestion and line-of-sight. A Tesla Robotaxi is a mobile, high-value vehicle whose earnings depend on demand density, utilization rates, insurance, cleaning, and charging.

Starlink’s program is already accepting host applications in multiple countries and describes the revenue split as ongoing. Tesla’s owner-network version remains more aspirational.

The company currently operates a limited company-controlled robotaxi service in select areas and has solicited interest from fleet buyers for Cybercab vehicles, while private Full Self-Driving owners have not yet been able to dispatch their own cars for paid rides at scale.

Tesla primes Cybercabs for 4K streaming and high bandwidth gaming with Starlink integration

Starlink is a satellite broadband service operated by SpaceX that uses a constellation of low-Earth-orbit satellites to deliver internet to locations where terrestrial broadband is slow, expensive, or absent. It has grown to millions of subscribers worldwide by selling direct residential, mobile, and enterprise terminals, and have become widely available at a wide array at retail locations like Target and Best Buy.

The Communities program extends that reach by letting hosts resell short bursts of capacity to people nearby, while also providing high-speed internet access to those who are simply around a Starlink user.

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Tesla just made its headlights even better through a software update

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Credit: @jojje167 on X

Tesla just upgraded its headlights through a software update, making them even better without any physical or hardware upgrade.

Tesla’s latest software update is quietly improving nighttime driving for a small number of owners. Version 2026.38 includes a new capability called Dynamic Headlight Leveling.

The feature automatically adjusts the aim of the low beams in response to driving conditions and nearby traffic, with the goal of giving the driver more usable light on the road while reducing glare for oncoming vehicles and traffic ahead.

Unlike Tesla’s matrix high-beam system, which selectively dims individual LED segments to create shadows around other cars, Dynamic Headlight Leveling physically tilts the low-beam projectors. Internal motors respond to changes in vehicle pitch.

When the car accelerates hard, climbs a steep grade, or carries extra weight in the rear, the headlights can otherwise point higher than intended. The software counters that movement in real time so the beam stays aimed at the road surface rather than into the eyes of other drivers.

Early indications reveal the update is reaching a limited set of vehicles, including certain Model 3 and Cybertruck examples in the United States and the United Arab Emirates. The rollout does not appear tied to a single hardware revision, and Tesla has not published a broader schedule. It is simply a common waiting game until your car receives it.

The change arrives against a backdrop of wider complaints about headlight glare. Some earlier Model 3 and Model Y vehicles were the subject of an NHTSA recall related to excessive low-beam glare; the software adjustment offers a potential mitigation for cars equipped with the necessary leveling hardware. It does not replace adaptive high beams where those are already available, nor does it alter the basic low-beam pattern itself.

Instead, it keeps an existing beam pointed where it is most useful.

For drivers who have received the update, the system requires no new settings or user input. The headlights simply respond as road conditions and traffic change. As the feature reaches more vehicles, it adds another example of Tesla using over-the-air software to refine existing hardware rather than waiting for a new model year. Nighttime visibility and reduced glare for others are the practical results owners are expected to notice first.

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