Tesla will issue a software update to address issues the NHTSA has found
Not a Tesla App
The NHTSA has found several issues with Tesla's FSD Beta software that they found concerning. Tesla has agreed to voluntarily fix the issues outlined through a future FSD Beta update.
The recall notice posted to the NHTSA’s website says that Tesla’s FSD Beta software “allows a vehicle to exceed speed limits or travel through intersections in an unlawful or unpredictable manner [which] increases the risk of a crash.”
Tesla was notified of the issues identified by the NHTSA. The agency is primarily concerned about the “operational characteristics” of FSD Beta. During these scenarios, the NHTSA is concerned that FSD Beta “could potentially infringe upon local traffic laws or customs, which could increase the risk of a collision if the driver does not intervene.”
The Issues The NHTSA Found
The NHTSA outlined the four issues below that they would like Tesla to address. Some of these have been long-standing issues and owners may be happy to hear they're being addressed.
Traveling or turning through certain intersections during a stale yellow traffic light;
The perceived duration of the vehicle’s static position at certain intersections with a stop sign, particularly when the intersection is clear of any other road users;
Adjusting vehicle speed while traveling through certain variable speed zones, based on detected speed limit signage and/or the vehicle’s speed offset setting that is adjusted by the driver; and
Negotiating a lane change out of certain turn-only lanes to continue traveling straight.
Meetings with Tesla
Tesla met with the NHTSA a number of times over the last two weeks to discuss solutions. Despite disagreeing with the NHTSA’s analysis, they’ve issued a voluntary recall and will provide a software update to remedy the issues identified.
According to Protect My Car, “a voluntary recall happens when the manufacturer is made aware of an issue that poses a safety risk.” The manufacturer will typically issue them to remove their liability. “These recalls never expire and the free car repair will be made no matter how old the vehicle is, how many miles it has, or how many owners have had the vehicle,” per Protect My Car.
NHTSA Investigates Tesla
The NHTSA has been investigating Tesla over its Autopilot and Full Self-Driving Beta software. Last summer, the regulatory agency requested more information from Tesla about their “phantom braking” complaints. Shortly after, they upgraded the investigation to an “Engineering Analysis” after a few reports of vehicles with Autopilot engaged crashed into stopped emergency vehicles.
“The investigation will assess the technologies and methods used to monitor, assist, and enforce the driver’s engagement with the dynamic driving task during Autopilot operation,” the NHTSA said at the time.
Although not directly aimed at Tesla, the NHTSA also recently launched an investigation as to whether hybrid-electric and electric vehicles from 1997 to present should have external speakers installed for pedestrian safety. In July 2022, the NHTSA received a petition that urged them to require all hybrid-electric and electric vehicles to have external noisemakers installed.
“The petitioner asserts that hybrid and electric vehicles to which the standard does not apply should be found to contain a safety defect. In support of the petition, the petitioner includes findings contained in a bill introduced in the House of Representatives in 2009, the Pedestrian Safety Enhancement Act of 2009, H.R. 734, 111th CONG. (2009).”
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In this article, we’ll cover Tesla’s updates on Optimus, batteries, and Tesla Energy.
Optimus
Tesla has been working away on their humanoid robot and continues to make progress in software and hardware.
First, Tesla is preparing the Fremont factory for the Optimus pilot production line, which is scheduled for completion later this year. Once it is, wider deployments of Optimus for internal use within Tesla’s facilities are expected as well. Tesla aims to have several thousand Optimus units working in its North American factories by the end of the year once the pilot production line is operational.
Tesla’s goals for production remain extremely lofty - 1 million units per year by 2030. However, they could face some challenges when ramping production.
Key components like the shoulder actuators use specialized permanent and rare-earth magnets, which are currently sourced from China. Due to recent Chinese restrictions on the overseas sale of these magnets, Tesla is seeking an exemption or alternative suppliers. They have not yet looked into modifying the shoulder actuator but will likely do so if they cannot obtain the necessary materials.
Batteries
Batteries are another item that Tesla’s teams have been working on behind the scenes for years now. The second generation of the 4680 - the Cybercell - has been IRA-compliant for some time now. This means that the Cybertruck is eligible for the US Federal EV rebate.
Tesla also achieved the lowest cost-per-kWh of any of its cells with the 4680 battery - and it is potentially one of the cheapest cells being manufactured by any vehicle battery manufacturer at this point. With dry-cathode still being worked on, Tesla may be able to squeeze more optimizations and cost efficiencies from the 4680 cells.
Additionally, Tesla is progressing with its plans for lithium refining and cathode production in the US, both of which are scheduled to commence in 2025. While the company says they’re no longer supply-constrained for non-LFP vehicle batteries, on-shoring production and sourcing critical minerals from nations outside of China will be key.
LFP batteries continue to be supplied-constrained - namely for the Tesla Energy division. LFP batteries and their materials are sourced from China. Due to tariffs and limited exports, Tesla is can’t obtain enough and is considering potentially building an LFP production facility in North America.
Energy
Tesla’s energy division is still experiencing some of the highest growth of any of its divisions. Year over year, Tesla saw a 154% increase in energy storage deployments, including both Megapack and Powerwall - for a total of 10.4 GWh deployed in just Q1 2025. While deliveries in energy storage remain volatile due to the nature of Megapack installations, Tesla expects growth to continue rapidly in this segment.
Tesla also deployed 1GWh of Powerwall 3 residential storage this quarter, marking its strongest quarter. Powerwall 3 has received positive feedback from customers, many of whom appreciate its new capabilities with its built-in inverter for solar.
Megapack is continuing to see demand increases, currently highlighted by utility-scale Megapack systems, as well as data centers requiring stable power delivery. Megafactory Shanghai is also online now and producing Megapacks - with an annual production capacity of 20GWh today and up to 40GWh in the future. The site has also produced over 100 Megapacks this quarter, which are all awaiting delivery.
There was a lot of interesting news from Tesla’s Q1 2025 Earnings Call, covering everything from FSD and Robotaxi - to the less glamorous but equally important Megapack and Powerwall.
Tesla is heavily leaning into artificial intelligence, and its insurance offering is just another example of how it’s improving its product or lowering costs by leveraging AI.
Tesla recently started offering an insurance discount in select states when drivers use FSD for at least 50% of their drives and now it’s introducing an AI to help handle customer claims.
Tesla has developed an in-house voiced AI agent that can assist customers in handling simple support requests for Tesla Insurance.
For customers calling in from those states, the new AI agent provides a unique way to address the most common support calls. And it’s not just answering common questions but actually making requested changes to the owner’s account.
Policy Changes
The first key item is that it automates policy changes. Simple policy updates, including adjusting your deductible or coverage limits, are now done via AI. For policyholders who are simply looking to make quick changes and don’t have any questions, this makes the process a lot quicker by not having to wait for a representative. Tesla isn’t eliminating representatives, but this could reduce the number of representatives required or reduce wait times.
Continue Where You Left Off
The second item here, highlighted by Raj Jegannathan from Tesla’s internal IT team, is that Tesla’s AI agent is able to offer summaries of the user’s last interaction with Tesla Insurance. It will summarize your last interaction and provide assistance on that particular topic if you need to continue it. That means that you don’t have to wait for a human to review your file - the AI will kick off right where you left off.
Tesla appears to be focused on improving efficiency and making support more accessible. While actual items like claims are left up to humans due to their inherently complex nature, this helps free up employees to handle more complex items. While there’s no doubt Tesla will continue to develop this AI like they do everything else, we may soon see it take on even more tasks.
More AI
This isn’t the first AI agent that Tesla has demoed - there is now a chat-based AI sales agent available on the front page of Tesla’s website, which is able to answer common questions on Tesla vehicles.
Tesla has also been improving their AI support tool available in the Tesla App is able to provide feedback on common issues and also guide users towards either solving the problem or placing a support request.
Tesla’s strategy here is to influence the cost-heavy areas associated with having humans address simple requests and instead leverage AI, which can offer instant answers and reduce support costs.
Roll Out to More States
While this new AI is currently limited to just 12 states, it is likely to follow Tesla Insurance’s expansion. Insurance seems to have been at a bit of a standstill lately. Tesla continues to improve features such as the improvements to Safety Score V2.2, but we haven’t seen Tesla roll out support to new states since it added Minnesota in November of 2022.
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