There’s an article in “The Drive” that’s been repeated in other media. Here’s a link if you want to read the whole article.
It’s not important in your day-to-day driving since few people use up all the electricity in their Tesla on a normal day. But, if you have lots of driving scheduled for a day, or if you’re taking a cross-country trip, you have to make allowances for this particularly Tesla problem.
The Results of the Tests
Edmunds, which does reviews on all cars, and which has rated the Tesla Model 3 as the number one best electric vehicle, found that none of the models of Tesla met the EPA range estimates as advertised by Tesla. None of the models. All the other electric cars easily went 20 to 50 miles past their EPA-rated ranges.
Tesla’s Response
Naturally, the Tesla engineers weighed in, but what they said was not very helpful. They said that the reason the Teslas failed to reach the EPA range is that Edmunds didn’t keep driving them until they couldn’t go an inch farther. Edmunds stopped driving when the range number on the screen went down to zero. So Edmunds repeated the testing and kept driving until the cars actually stopped. Tesla calls this a safety buffer.
Don’t Plan on Using the Safety Buffer
Don’t plan on using the safety buffer. It’s terrible for the battery. It’s just as bad as charging your battery up to 100% and then letting it sit overnight. Don’t do that either. Bad.
Be Kind to Your Battery
We want our batteries to last as long as the rest of the car. So, in my case, I charge to 80% every night. That way, I’m not damaging the battery, and I have more miles than I need for day-to-day driving. I do plan on taking the Tesla on road trips once this furshlugginer pandemic is over. I have the SR+ which, in theory, can go 250 miles on a charge. I won’t plan on 250 miles between supercharges. When my car was new, and I had 1,000 miles or six months of free supercharging, whichever came first, I didn’t actually need any supercharging. Not going anywhere. Pandemic y’know. The six months came first.
My Supercharging Experience
But, since supercharging was included in the price of my car, any time I needed to go somewhere near a supercharger, I went ahead and used the service. Here’s what I found. When the battery is low, the supercharger gives extremely rapid charging. I can’t tell you the exact rate of charge because different superchargers give different rates of charge depending on which generation of supercharger you’re using. But as a general rule, you’ll get extremely rapid charging when the battery is low. You’ll probably get to 80% in 30 to 40 minutes. That last 20% will take longer. A lot longer.
Suggested Strategy
You’ll probably do better in total trip time if you don’t wait around for the last trickle of energy to fill your battery to 100%. Between 80% and 90%, the charging goes painfully slowly. Between 90% and 100%, the charge slows to a trickle. You’ll stop a bit more often, but you’ll spend less total time on the chargers during your trip if you just charge to 80% each time you need to charge. When I take my trip, I’ll be sure to let you know how it goes.
Public Health Advice
One last thought for car trips. Elon Musk gives you video games to entertain yourself during a supercharger stop. If you’re on a trip, don’t play the video games. Get out of the car and walk around. Sitting in a car for long periods of time can cause blood clots in your legs. Don’t let that happen.
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Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
Tesla has pioneered the use of single-piece castings for the front and rear sections of their vehicles, thanks to its innovative Gigapress process. Many automakers are now following suit, as this approach allows the crash structure to be integrated directly into the casting.
This makes the castings not only safer but also easier to manufacture in a single step, reducing costs and improving repairability. For example, replacing the entire rear frame of a Cybertruck is estimated to cost under $10,000 USD, with most of the expense coming from labor, according to estimates shared on X after high-speed rear collisions.
These insights come from Sandy Munro’s interview (posted below) with Lars Moravy, Tesla’s VP of Vehicle Engineering, highlighting how these advancements contribute to the improvements in Tesla’s latest vehicles, including the New Model Y.
However, with the new Model Y, Tesla has decided to go a different route and eliminated the front gigacast.
No Front Casting
Tesla’s factories aren’t equipped to produce both front and rear castings for the Model Y. Only Giga Texas and Giga Berlin used structural battery packs, but these were quickly phased out due to the underwhelming performance of the first-generation 4680 battery.
Tesla has gone back to building a common body across the globe, increasing part interchangeability and reducing supply chain complexity across the four factories that produce the Model Y. They’ve instead improved and reduced the number of unique parts up front to help simplify assembly and repair.
There is still potential for Tesla to switch back to using a front and rear casting - especially with their innovative unboxed assembly method. However, that will also require Tesla to begin using a structural battery pack again, which could potentially happen in the future with new battery technology.
Rear Casting Improvements
The rear casting has been completely redesigned, shedding 7 kg (15.4 lbs) and cutting machining time in half. Originally weighing around 67 kg (147 lbs), the new casting is now approximately 60 kg (132 lbs).
This 15% weight reduction improves both vehicle dynamics and range while also increasing the rear structure’s stiffness, reducing body flex during maneuvers.
Tesla leveraged its in-house fluid dynamics software to optimize the design, resulting in castings that resemble organic structures in some areas and flowing river patterns in others. Additionally, manufacturing efficiency has dramatically improved—the casting process, which originally took 180 seconds per part, has been reduced to just 75 seconds, a nearly 60% time reduction per unit.
Advancements in die-casting machines and cooling systems have allowed @Tesla to dramatically reduce cycle times and improve dimensional stability. pic.twitter.com/WB5ji67rvV
Tesla’s new casting method incorporates conformal cooling, which cools the die directly within the gigapress. Tesla has been refining the die-casting machines and collaborating with manufacturers to improve the gigapress process.
In 2023, Tesla patented a thermal control unit for the casting process. This system uses real-time temperature analysis and precise mixing of metal streams to optimize casting quality. SETI Park, which covers Tesla’s manufacturing patents on X, offers a great series for those interested in learning more.
The new system allows Tesla to control the flow of cooling liquid, precisely directing water to different parts of the die, cooling them at varying rates. This enables faster material flow and quicker cooling, improving both dimensional stability and the speed of removing the part from the press for the next stage.
With these new process improvements, Tesla now rolls out a new Model Y at Giga Berlin, Giga Texas, and Fremont every 43 seconds—an astounding achievement in auto manufacturing. Meanwhile, Giga Shanghai operates two Model Y lines, delivering a completed vehicle every 35 seconds.
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