Tesla is nearing a pivotal moment in its journey and the automotive industry. According to a detailed report by Reuters, the company is on the brink of a groundbreaking manufacturing evolution, set to revolutionize the production of its next vehicle and set a new standard for the future of vehicle creation.
Drawing on insider knowledge from five anonymous sources, the report sheds light on Tesla's innovative gigacasting process, poised to redefine the manufacturing landscape and help Elon Musk realize his ambition of halving production costs. A decision on this significant shift could be made later this month.
A Single-Frame Approach
The key to this disruption lies in Tesla's commitment to unboxed manufacturing - a strategy introduced by Musk in March. At its core, this strategy focuses on the die-casting of nearly the entire complex underbody of an EV in one singular piece, reducing the traditional assembly of around 400 parts in a conventional car to a singular entity.
Tesla has used technology in several areas of its operation, notably a recent single-piece front casting for the Model Y that resulted in 169 fewer pieces and 1,600 fewer welds.
Tesla's unboxed strategy could roll out soon, drastically cutting production time and costs. According to Reuters, Tesla's forthcoming $25,000 car presents the perfect canvas for this one-piece casting revolution, bearing a simpler underbody resembling "a battery tray with small wings."
The Material Difference
To bring this vision to life, Tesla's global team, based across the UK, Germany, Japan, and the US, has leveraged 3D printing and industrial sand. Utilizing binder jets, which construct molds layer by layer through the deposition of a liquid binding agent on a sand layer, the team can quickly create and adapt prototype molds. This process significantly cuts the traditional costs associated with metal prototype creation, paving the way for rapid iteration at just 3% of the usual expenditure.
Beyond molding, Tesla has also been developing special alloys to overcome challenges in crashworthiness and other attributes associated with the different behaviors of these materials in sand and metal molds. These alloys, aligned with a fine-tuned molten alloy cooling process and post-production heat treatments, have potentially set the stage for a large-scale manufacturing revolution.
Tesla is deliberating on the exact nature of the die-casting process - whether embracing high-pressure techniques for speed or opt for slow alloy injection to ensure quality and versatility. The choice between these methods implicates not only the complexity of the car frame but also dictates the need for potentially more significant factory buildings and Giga Presses boasting a staggering clamping power of over 16,000 tons.
Strategic Shift to Giga Texas
This aligns with recent insights from Walter Isaacson's biography of Elon Musk, illustrating a strategic shift in Tesla's operations. Initially slated for Mexico, the production hub for the next-generation EV platform will now reside in Giga Texas. This will allow Musk to keep a closer eye on the development, design engineers and the manufacturing hub to facilitate immediate feedback and streamline processes. The book also said that Giga Mexico would still play a significant role, but now it seems it would be where the new technology would be housed after being perfected in Texas.
As the clock ticks down to Tesla's final decision, one thing remains clear: a potential transformative moment in EV manufacturing is on the horizon, promising a future where Tesla's EVs are more affordable, attainable, and revolutionary than ever before. It is not just a step but a gigantic leap toward the future of automotive manufacturing that only a visionary like Musk could envision and endeavor to achieve.
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Ganesh Venkataramanan, Tesla’s project lead for its ambitious Dojo supercomputer project for the past five years, has left the company. Bloomberg reported this development, stating that the news was confirmed by sources familiar with the matter. Peter Bannon, a former executive at Apple Inc. and a director at Tesla for the last seven years, has now taken the helm of the project.
Venkataramanan's departure from Tesla last month is now stirring conversations about the potential impacts on Tesla's future initiatives. His contributions to the Dojo project have been pivotal, especially in designing the custom D1 chip that powers the supercomputer. Venkataramanan, with his extensive experience, including a significant tenure at Advanced Micro Devices Inc. (AMD), was a crucial asset in setting up Tesla’s AI hardware and silicon teams in 2016.
Dojo: A Cornerstone for Tesla’s Self-Driving Aspirations
The Dojo supercomputer is a critical element of Tesla's strategy to enhance its self-driving capabilities. Designed to train machine learning models integral to Tesla's autonomous systems, Dojo processes vast amounts of data captured by Tesla vehicles. This rapid data processing is essential for improving the company’s algorithms, with analysts suggesting that Dojo could be a significant competitive advantage for Tesla. In a recent estimation by Morgan Stanley, the project could potentially add $500 billion to Tesla’s value.
Elon Musk has been vocal about the company's commitment to the Dojo project, planning an investment exceeding $1 billion by the end of 2024. The project's importance was underscored in Tesla's decision to shift from relying on Nvidia Corp.’s supercomputers to developing Dojo, poised to rival systems from Hewlett Packard Enterprise Co. and IBM.
Looking Ahead: Impact and Future Prospects
The recent leadership changes raise questions about the future direction of the Dojo project. Venkataramanan's exit, coupled with the departure of another critical artificial intelligence player from Tesla last year, Andrej Karpathy, signals a transition period for the company’s AI and self-driving teams.
However, Tesla's robust talent pool, blending experienced and emerging professionals, offers a silver lining. Bannon's promotion to lead the Dojo project is seen as a strategic move, leveraging his experience and insights gained from his tenure at Apple. Moreover, the recent installation of Dojo hardware in Palo Alto, California, marks a step forward in centralizing and enhancing the project’s capabilities.
Tesla’s ambitions for Dojo extend to making it one of the world’s top supercomputers. The company envisions reaching a computational capability of 100 exaflops* by October 2024, a testament to its commitment to advancing artificial intelligence and self-driving technology.
* Confused about "exaflops?" "Flops" stands for Floating Point Operations Per Second. It's a way to measure how fast a computer can process data. "Exa" means a billion billion, or 1, followed by 18 zeros (1,000,000,000,000,000,000). So, when we say a computer can perform 100 exaflops, it can do 100 billion billion calculations per second. That's incredibly fast!
Tesla is adding a new 'High Fidelity Park Assist' feature in this year's Holiday Update
Tesla
Following initial reactions to Tesla's 2023 Holiday Update, Elon Musk acknowledged the need for improvement, stating, "We need to step up our game." His post on X was followed by Tesla shedding more light on the Holiday Update than what was in the initial leak.
Call me old, but I remember a time when you bought a car, and that was it; the dealer and manufacturer didn’t give you anything else. So is the Tesla community acting a little bit spoiled here? Absolutely. But it also shows how high Tesla has set the bar with its previous Holiday Updates.
Initial Release and Feedback
The initial release of the 2023 Holiday Update, version 2023.44.25, received mixed reactions from the Tesla community, with some owners expressing disappointment over the lack of groundbreaking new features. But the newly announced features may serve as better stocking stuffers.
The initial rollout included something owners have been asking for, the blind spot monitor. The camera that turns on when you change lanes will now have a red color added if there is something in your blind spot. It’s not clear whether it will be accompanied by a tone.
Tesla’s blind spot warning in this year’s holiday update
Here are other features in the leaked update that are being tested by employees:
Navigation and Safety Features: Including symbols for speed cameras, stop signs, and traffic lights in navigation, and the automatic 911 call feature in case of an accident.
Trip Planning via Tesla Mobile App: Allowing for more detailed trip planning, including multiple stops and charging points.
Apple Podcasts Integration: Allowing users to sync with Apple devices for a seamless podcast experience, directly addressing the demand for a richer in-car entertainment system.
New Games and Enhancements: The update brought updates to Tesla Arcade, with Beach Buggy Racing and Polytopia Diplomacy updates, as well as the Vampire Survivors Chilling update.
Light Show Improvements: There’s a new light show that’s included with your vehicle. You’ll also be able to upload several light shows on a single USB drive and pick one from the vehicle, instead of having to use multiple USB drives, one for each light show.
More Live Sentry Mode Cameras: You will now be able to view the B-pillar cameras directly from the Tesla app. This brings the number of viewable cameras in the app up to seven. The only ones still missing are the alternative front-facing cameras that are telephoto and wide-angle, which wouldn’t bring much additional value. Although the B-pillars are viewable in the app with this update, they will still not be used to record during Dashcam or Sentry Mode events.
High-Fidelity Park Assist
Tesla's new parking assist feature will dynamically recreate scenes in real-time
Tesla
In response to the feedback and Musk's statement, Tesla unveiled additional features in its updated holiday update, including an improved park assist with enhanced visualizations.
This feature provides a 3D reconstruction of the vehicle's surroundings while parking, akin to a 360-degree camera system found in other high-end vehicles. The system is clearly leveraging improvements to Tesla Vision to create the surrounding environment, such as cars, pillars and walls.
This feature also appears to change the color of objects depending on how close they are to your vehicle. In the image we can see the pillars are orange, but if we look closer, the object behind the vehicle is also orange near the bottom. The sides of the vehicles next to the Tesla also have a slight hint of orange, indicating their proximity.
However, it looks like this feature may be even better than it initially looks. The vehicles in the image aren’t just predefined 3D models that Tesla created, like the ones used in Autopilot visualizations. These models appear to be dynamically created using vision, so that no two cars would look alike, much more similar to what LiDar is able to achieve. The visualization provides a true representation of the environment around the vehicle. You can see that each vehicle is made up from layers and have blurred edges toward the rear, where the camera would have a hard time seeing.
These 3D models could be a sneak peek at the future of FSD visualizations.
High-Fidelity Park Assist Requirements
A big question on everyone’s mind is who will receive this new park assist feature. Tesla didn’t address this in their post on X besides providing a disclaimer that the features in the holiday release are subject to model and region availability. Tesla often likes to test features in select markets before making them available everywhere. It’s hard to say whether that will be the case here. There likely aren’t any legal ramifications around providing visualizations, so that’s a good sign that this feature will be available in most regions, either in the holiday update, or soon afterward.
However, there are still questions around which models or hardware will be required. From the image shared, we can see it’s offered on a Model Y, removing any speculation of it possibly requiring the HD radar in the new Model S/X. We also don’t think it will require FSD hardware 4.0, so the remaining questions are whether it requires MCU 3, or the FSD package.
Given that Tesla is calling this Park Assist, it doesn’t appear to be linked to Auto Park, which is a FSD package feature. When Tesla rolled out visual and audio alerts for vehicles without ultrasonic sensors, it called the feature Park Assist, and that was available to all owners.
Whether this improved Park Assist feature requires a vehicle with MCU 3 will depend on the level of processing power required. It’ll certainly require more than the current visualizations given that its building the scene in real-time, so we’re hopeful that it’ll work on MCU 2 vehicles too, but we just don’t have enough information right now to make the call.
Custom Lock Sounds
Soon you'll be able to choose a custom locking sound for your car
Not a Tesla App
Tesla also announced a fun and whimsical feature that allows owners to customize the lock sound of their Tesla. No longer will you need to listen to the car’s horn when it locks as you walk away. Now you’ll be able to customize the lock sound of the vehicle. Tesla is including several options, including sounds like a screaming goat, a jingle, a rubber ducky, a quack sound, an old school horn and applause. However, you’ll also be able to upload your own file to create a truly unique experience.
You can pick anything, from a bird’s tweet to a favorite video game sound. You’ll only be limited by the maximum upload file size, which according to a Tesla engineer, is a 1MB file in WAV format, which is roughly about 40 seconds at good quality.
This feature is possible due to the vehicle’s external pedestrian warning speaker. So if you have Tesla’s Boombox feature or your vehicle makes a sound when traveling under 20 MPH, then you should receive this fun enhancement.
Rear Seat Audio and Gaming
You'll now be able to play games on Tesla's rear screens
Tesla
Enhancing the Tesla Arcade experience, passengers in the rear seats can now play games on the rear touchscreen. This feature, especially when paired with Tesla Arcade’s compatibility with PS4, PS5, Xbox Controllers, and rear-screen Bluetooth Headsets, is a welcome addition for families and long trips.
Much like the new Model 3, which received rear audio over Bluetooth support in the 2023.38 update, the new Model S and Model X will also receive this ability in the holiday update.
New Game - Castle Doombad
Tesla announced one other feature in the 2023 holiday update that hadn’t been previously leaked, and that’s a new game called Castle Doombad. Castle Doombad is a single player tower defense, puzzle-like game that’s currently available on iOS and Android, but has an upcoming release on PC and the Nintendo Switch. This game is expected to require MCU 3.
Release Timeline
The rollout of the 2023 Holiday Update is expected to follow a similar timeline to last year. Tesla announced that the update will roll out starting next week. However, it’s not clear whether this will also include FSD Beta testers that are on a 2023.27 update.
Like a spoiled child on Christmas morning, Tesla owners still ask, “Is that it?” Well… possibly, but there may be more to look forward to early next year as Tesla builds off of the new High-Fidelity Park Assist feature.
Advanced Smart Summon: Upgrading the Smart Summon feature to be more intuitive and efficient, especially in complex parking scenarios.
Reverse Summon / Park Seek: What happened to Tesla dropping its passengers and driver off at the location and then finding a parking spot on its own?
Enhanced FSD Visualizations: Expanding the Full Self-Driving visualizations to more regions or models or completely recreating the FSD visualizations using the same neural networks Tesla is using for the High-Fidelity Park Assist feature.
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Tesla Android Project enables you to run Android apps in your Tesla. The platform is Open Source and you can deploy it on your own Raspberry Pi 4. Consider supporting the initiative by donating or purchasing the Compute Module 4 Bundle that delivers the best experience. Get $20 off by using the code: NotATeslaApp
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TeslaBox delivers real-time video notifications for every Sentry and Dashcam event, continuously backs up all footage without hitting record, and enables remote file browsing. No wiring. Installs alongside your standard USB stick.
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