Tesla Is on the Verge of Another Manufacturing Breakthrough

Tesla is set to increase their manufacturing lead

Tesla

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.

Tesla Is Now Offering Cybertruck Test Drives [List of Locations]

@brandonhd

Tesla has begun to reach out to customers in the United States and is offering demo drives of the Cybertruck on an invite-only basis. @brandonhd on X shared the first invite image, and it looks like it's going out quite quickly to multiple locations that have Cybertrucks on display.

Up until now, display vehicles have been for just that – looking, but no touching. Some Tesla delivery centers and showrooms have also allowed viewers to take a seat inside and open it up, but most are still locked away behind the velvet rope.

It’s exciting to see that Tesla has begun to demo them – and it can only be so long until demo drives open up to everyone.

Advisor-led Demo

This Demo Drive is led by a Tesla Advisor – while you’re driving, the advisor will be in the passenger seat, walking you through the experience. They’ll explain steer-by-wire, off-road controls, and will introduce new-to-Tesla buyers to all the features that are currently available.

Once FSD V12.5 comes to the Cybertruck, we’re sure they’ll be demoing its capabilities FSD capabilities as well.

Locations

The list of locations so far for demo drives appears to be fairly limited, but we will hopefully see demo drives roll out throughout the United States, and eventually Canada too. Here is the current list of city/state locations that have seen demo drive invites.

• Manhasset, New York

• West Covina, California

• Los Angeles, California

• Houston, Texas

• Orlando, Florida

• Westmont, Illinois

• Tucson, Arizona

• Phoenix, Arizona

• Delaware

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Musk Confirms 'Actually Smart Summon' is Coming in a Revision of FSD V12.5

Not a Tesla App

Actually Smart Summon, the successor to Tesla’s Smart Summon feature, has been confirmed to be coming as soon as next month as per Elon Musk. Colloquially known as “ASS”, Actually Smart Summon is supposed to improve on the regular Smart Summon capabilities, which have historically used ultrasonic sensors (USS) to navigate parking lots.

We’re looking forward to Actually Smart Summon, and we’re quite excited about what other features will be unlocked once it finally shows up at our doorstep.

Vision-based Improvements

ASS is supposed to bring Smart Summon to vehicles that don’t have USS – using Tesla Vision. Most recently, Tesla has brought Autopark to vehicles without USS, and Vision-based Autopark has been a huge success. It is faster, more reliable, and smoother than the older USS-based solution. It can also park and maneuver in tighter locations.

Just recently, Tesla returned the Model X’s self-presenting doors, using Tesla Vision. Vision has seen some fantastic improvements, and many people are waiting for ASS to bring forth these improvements to Smart Summon.

Smart Summon Today

Today, Smart Summon is sometimes useful at best, usually a party trick, or downright dangerous at worst. It’s excellent and best used in straight lines, where you have a clear line of sight of the vehicle, and can stop it if doesn’t see an obstacle.

I used Smart Summon today, just before writing this article – my 2022 Model Y (with USS) – did manage to show up just fine – in a straight-line location from where I was parked, after exiting the parking spot fairly cleanly. However, I’ve previously used Smart Summon and have had the vehicle turn towards obstacles, such as cart returns or curbs. Overall, it’s a sometimes-useful feature that has a lot of drawbacks right now.

Smart Summon is also restricted to a certain distance – and it's pretty small. The max distance is shorter than most parking lots, being only about 215 ft (65m). If you’re lucky enough to park close, it's very useful to bring your car right to you.

Actually Smart Summon

ASS will bring FSD V12-like capabilities to Smart Summon – the vehicle will primarily use Vision to drive toward you (or the location you’ve indicated). ASS has been supposed to be coming since about September 2022 and has seen many delays – we’re almost at the 2-year point today.

We’re looking forward to Actually Smart Summon being able to bring the vehicle – safely – right to you. ASS is also one of the key steps towards bringing some other cool features that Elon Musk has previously mentioned – Park Seek and Banish Autopark.

We’re also hopeful that Actually Smart Summon will increase the maximum range a vehicle can be summoned, because the current range is fairly small. Alongside Park Seek and Banish Autopark, we’re closing in on a Robotaxi-based future.

Park Seek and Banish Autopark

When the FSD v12.4 showed up, Elon also mentioned that going forward, vehicles would automatically park themselves when arriving in a parking lot – Park Seek – and that if you got out of the car at the entrance to a business, you could get it to automatically park itself in the parking lot – Banish Autopark. These are two features that are needed for Robotaxi to work – which itself is delayed to October 10^th of this year. We’re looking quite forward to them – as in combination with Actually Smart Summon, Tesla has reached the cusp of vehicle autonomy.

A vehicle that arrives, driverless, at the location you’re at, then drives somewhere, parks itself there, and waits for you – is the definition of a Robotaxi.

While we’re likely to have to wait for Banish Autopark and Park Seek just a bit longer, Actually Smart Summon being around the corner is exciting! Gone will be the days of having to run out to your car when you forgot your umbrella – your car will just come right to you instead.

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