Tesla opens up it's charging connector to other manufacturers
Tesla
Tesla removed all the patents in the lobby of its Palo Alto headquarters prompting Elon Musk to explain in a blog, "They have been removed, in the spirit of the open source movement, for the advancement of electric vehicle technology." The post is from 2014; he continued, "Tesla Motors was created to accelerate the advent of sustainable transport." That policy has been held, but some designs have not been for public consumption, including its industry-leading charging connector — until now.
A new post on the Tesla website reiterates Musk's words from eight years ago. "In pursuit of our mission to accelerate the world's transition to sustainable energy, today we are opening our EV connector design to the world," states the company. "We invite charging network operators and vehicle manufacturers to put the Tesla charging connector and charge port, now called the North American Charging Standard (NACS), on their equipment and vehicles."
Strategic Play
It is a generous move but also a clever, strategic play. There is no doubt that electric vehicles are here to stay. The question is, what will the nozzle be on the gas pump of the future? With more private companies getting into the EV charging game, this move makes it easy for them to add the Tesla connector to their equipment. Tesla has already been in discussions with some of those companies. The post states, "network operators already have plans in motion to incorporate NACS at their chargers, so Tesla owners can look forward to charging at other networks without adapters.
The company says that its connector, the NACS, is North America's most common charging standard. Tesla states, "NACS vehicles outnumber CCS two-to-one, and Tesla's Supercharging network has 60% more NACS posts than all the CCS-equipped networks combined." EV owners who don't have NACS will have fewer options to charge up. Car manufacturers are already racing to get into the EV game and don't also need to try to play catch up to Tesla's already well-established charging network. Tesla states, "we look forward to future electric vehicles incorporating the NACS design and charging at Tesla's North American Supercharging and Destination Charging networks."
It's ingenious to drop the Tesla brand off and name it the North American Charging Standard. It will make it much easier for competing brands to swallow their pride and use superior technology. The system is the most tested EV charger in the world, and the company reports it has "20 billion EV charging miles to its name." It is also far better than the Combined Charging System (CCS 1), offering twice the power in half the size.
A petition to the U.S House of Representatives was started in July 2022, asking for the Tesla connector to be the charging standard for the U.S. A solar-powered car company named Aptera is behind the Change.org petition that has more than 40,000 signatures. It links to reports showing the Tesla connector wins in every category tested.
While CCS 2 has become the charging standard in Europe, the market is wide-open in North America where the CCS 1 connector has not yet taken off.
There is a comment on the Change.org website worth noting. Eric Stewart posted, "The Tesla connector is what engineers would choose if politics didn't make these things about ego." Now, if NACS is not the standard, it will be crystal clear that Stewart is right.
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.
![A Look at the Tesla Cybertruck’s Crumple Zones [VIDEO]](https://www.notateslaapp.com/img/containers/article_images/cybertruck/cybertruck-crash-test.webp/e43ef2433bd6e44ae8db63421604a4fb/cybertruck-crash-test.jpg)
