Tesla's new hardware 4.0 is close, but don't expect retrofits
Tesla
Tesla's upcoming FSD hardware, hardware 4.0, is nearing completion, and although there is limited information about it, it sounds like it'll bring significant improvements. It's yet to be known when the new hardware will debut, but it is clear Tesla will not be retrofitting the existing fleet.
"The cost and difficulty of retrofitting hardware 3 with Hardware 4 is quite significant. So, it would not be, I think, economically feasible to do so."
Musk said Hardware 3 is five years old but, "is still the most efficient inference computer in the world."
What Will Be In Hardware 4.0
It's believed that the new hardware will use 5-megapixel cameras; the current cameras are 1.2 megapixels. Also, some leaked pictures appear to reduce the amount of front-facing cameras from three to two and allow for heaters and fans.
The higher-resolution cameras will give Autopilot a significant advantage when trying to determine objects that are further away because of the additional pixels. An object that is 100 or 200 feet away may only be made up of a few pixels, but with almost 5x the resolution, the newer cameras will be able to more accurately determine what the object is. This is also true for everything else, such as the curvature of the upcoming turn.
In addition to the cameras, we know that there will be a new FSD computer which is expected to be about 4x more powerful than the current FSD computer in hardware 3.0. Part of this additional processing power will no doubt go toward processing the additional 32 million pixels that the newer cameras will provide.
However, hardware 4.0 will be about more than just a faster computer and better cameras. It is also expected to include an HD radar, which Elon Musk has talked about in the past and has been seen in Tesla's FCC filings. The addition of a high-definition radar could provide a significant advantage to FSD by sensing objects that cameras alone can't.
The difference between radar and HD imaging radars
fierceelectronics.com
When Musk talks about the upgrade from hardware 3.0 to hardware 4.0 not being feasible, that likely means there may be even more to it than we already know. This could just be due to the new radar, new power, or space requirements for the new computer, but it's also possible that there could be more to hardware 4.0 than we know.
We know that Tesla's Robotaxi is already in development and this is a vehicle that is expected to be completely driverless. Tesla won't have the convenience of having a driver behind the wheel here. This could mean that Tesla may need to add additional hardware that we haven't heard about it. This could be different camera placements, or something entirely different.
What we know for sure is that hardware 4.0 will include higher-res cameras, a faster computer and likely an HD radar, but there could be even more that makes it infeasible to retrofit older vehicles.
Elon Talking About Hardware 4
The video below is queued up to the part where Elon talks about FSD hardware 4.0 (segment begins at 30:10).
Hardware 3.0 Will Be Capable of FSD
Musk put the argument into perspective for those who may want to wait. "Hardware 3 will not be as good as Hardware 4, but I'm confident that Hardware 3 will so far exceed the average -- the safety of the average human." He then broke it down further, "let's say, for argument's sake, if Hardware 3 can be, say, 200% or 300% safer than human, Hardware 4 might be 500% or 600%." In fact, stats show that Teslas operating with Autopilot engaged at 10 times safer, and that is with Hardware 3.
Will Teslas With HW3 Really Be Autonomous?
Listening to Musk's choice of words is interesting, he seems to have steered away from words he may have used in the past, such as referring to level 5 autonomy, or using the words robotaxi, or autonomous driving. Instead, he chose to say hardware 3 would exceed the safety of an average human. That could mean that Tesla's current FSD implementation will always require a driver behind the wheel, but the combo of Tesla's FSD system and the driver as a backup would be multiple times safer than a human.
Tesla has to be Careful
The CEO had a tightrope to walk when talking about the existing hardware and what the future system will look like. You may recall in late 2022 when demand for Teslas started to slow down. Many observers believe it was due to the impending tax credits the Inflation Reduction Act would provide for buyers of electric vehicles. Tesla cut prices for the last few days of 2022 to match tax credits, but only for consumers who took delivery before the end of the year.
Now, a new dilemma, how many consumers will wait for the latest hardware? There is no timeline for it, the only vehicle we know it will be in is the Cybertruck, but the Cybertruck won't start production until this summer.
FSD Hardware 5.0
Musk has a point. Hardware 3 is fantastic, but with a new one that is twice as good on the horizon, it losses some exceptionality. Then there is this next line by Musk, "with Hardware 4 coming and then Hardware 5 beyond that where there are significant leaps." So yes, we already have talk of Hardware 5. However, this is not expected for several years.
Once again, mark your calendar for March 1, 2023. Tesla is hosting Investor Day, and along with more information on the next-generation vehicle, we may get more details on hardware 4.0 and what it will contain.
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.