Tesla's gigacast greatly reduces parts, welds and vehicle production time
Tesla
New insights into Tesla's manufacturing innovations have emerged, suggesting the automaker is not just nearing but actively implementing groundbreaking advancements in its gigacasting technology. Reports from the Shanghai Securities News and posts from X.com user @zhongwen2005 unveil Tesla's successful adoption of an upgraded gigacasting process at its Shanghai Giga Factory, focusing primarily on the Model Y's rear bottom plate assembly system.
This revelation is a pivotal update to earlier reports, indicating that Tesla is realizing its commitment to unboxed manufacturing and is on the brink of revolutionizing vehicle production. The upgraded gigacasting technology allows the die-casting of almost the entire complex underbody of an electric vehicle in one piece, significantly reducing production costs and assembly components.
New Technology Now in Use
According to the new information, the application of this integrated die-casting technology has led to a remarkable 40% reduction in related production costs and over 10% weight savings compared to traditional methods. These advancements are especially pertinent as Tesla explores manufacturing possibilities for its forthcoming $25,000 car, which presents an ideal opportunity to deploy this one-piece casting innovation.
Tesla's pioneering approach, involving 3D printing, industrial sand, and the development of specialized alloys, is further fine-tuned with the introduction of version 2.0 of its integrated die-casting technology. The amalgamation of rapid prototyping, material innovation, and advanced casting techniques underscores Tesla's relentless pursuit of manufacturing excellence, setting the stage for a large-scale manufacturing evolution.
This strategic shift and technological progression are aligned with the insights shared in Walter Isaacson's biography of Elon Musk, depicting a transition in Tesla's operational hubs. The Giga Texas facility emerges as a focal point for the development and perfection of this next-generation EV platform, with Giga Mexico anticipating the subsequent housing of the new technology.
The Competition is Playing Catch-up
As the electric vehicle market grows increasingly competitive, such innovations are crucial. The upgraded gigacasting technology places Tesla at the forefront of manufacturing efficiency and sets a precedent for other manufacturers. Toyota recently unveiled its own gigapress, and Chinese EV makers, including Xpeng and Geely's Zeekr, are adopting gigapressing technology to decrease vehicle weight and cut costs.
As Tesla continues to refine and implement its upgraded gigacasting technology, the company is not merely taking a step but making a significant leap toward redefining automotive manufacturing. The integration of this advanced technology at its Shanghai plant illustrates the tangible strides Tesla is making in realizing Elon Musk's vision of halving production costs and making electric vehicles more affordable and accessible.
The latest developments confirm that a transformative moment in EV manufacturing is not just on the horizon but actively unfolding. Tesla's commitment to innovation and the successful application of upgraded gigacasting technology underscore its position as a leader in the automotive industry, driving towards a future where electric vehicles are increasingly revolutionary and attainable.
Subscribe
Subscribe to our newsletter to stay up to date on the latest Tesla news, upcoming features and software updates.
Tesla’s much-anticipated official entry into the Indian market appears to be shifting to a higher gear, with recent reports from Business Standard (paywall) indicating that Tesla is now looking into establishing Gigafactory India. Business Standard points to Tesla exploring land options in Satara, Maharashtra.
Satara is about 250km (155 mi) from the Port of Mumbai, placing it in an excellent location to easily receive parts and materials from other countries, as well as ship completed vehicles elsewhere around the world. The potential facility is reportedly planned as a “Completely Knocked Down” or CKD assembly plant, which means that Tesla would import parts and then assemble them locally.
This is key to Tesla’s strategy in addressing India’s traditionally high import tariffs on fully built vehicles, which have been a major hurdle for Tesla in the past. This push aligns with India’s updated EV policy, which calls for reduced import duties on EVs priced at $35,000 USD or above for companies that commit to investing at least $500m USD in local manufacturing facilities between 2024 and 2027.
According to the report, Tesla is prepared to invest substantially more, with figures around $2-3 billion USD cited for a plant capable of doing final assembly on up to 500,000 vehicles. Tesla supposedly aims to roll out the first locally assembled vehicle from the facility no later than March 2026.
Building the Indian Foundation
Beyond just manufacturing plans, Tesla has been actively laying the groundwork for its future Indian operations. Tesla has reportedly finalized leases for its first showrooms in Mumbai and Delhi - two of the largest cities in India. An office space in Mumbai to headquarter Indian operations is also on that leasing list.
Tesla has also begun to hire its initial tranche of employees, with over 30 positions already posted. Tesla is also hiring Autopilot Vehicle Operators in several locations, indicating that Tesla intends to test at least the FSD suite in one of the most complex traffic situations around the world.
Elon Musk also confirmed that he plans to visit India and speak to the Indian Prime Minister, likely to broker a deal focusing on building out Tesla’s presence and bringing new technology to the country.
The road to India has not been without its complexities. Reports confirmed the resignation of Prashanth Menon, Tesla's India head, with oversight of Indian operations temporarily shifting to Tesla's China team. Furthermore, earlier discussions with potential joint venture partners, such as Hyderabad-based Megha Engineering for land acquisition, reportedly did not materialize, leading Tesla to explore other avenues and locations like Satara.
Despite all the setbacks, Tesla’s efforts indicate that they are more determined than ever to make a formal and official entry into the Indian market.
Tesla’s software updates often contain far more than the release notes show, whether they’re undocumented features or preparation for the next big thing. The 2025 Spring Update is no exception - it’s filled with undocumented changes and, of course, new, inaccessible code that points to upcoming features.
Tesla hacker greentheonly on X has been digging into update 2025.14 and found some intriguing additions and hints about what’s coming next, so let’s take a look.
Grok Incoming
New hidden UI elements have been found pointing towards the integration of a Grok-powered smart assistant for Teslas. This includes references to a “personality” button, just like the Grok app. Tesla is likely hard at work on an advanced conversational AI and integrating the ability to control your vehicle.
Grok is the smart assistant that’s expected to replace the ancient voice commands that are available today. However, expect anything beyond vehicle commands to require Tesla’s Premium Connectivity.
While none of these new elements are active just yet, it is a good indication that it is likely on its way quite soon.
Siren Detection UI Removed
Code related to user-facing elements for siren detection has now been removed. We’ve confirmed that the orange dot is still in place with the Spring Update, but elements related to future changes and a UI for siren detection have since been removed from the code base.
Removals don’t indicate much - Tesla could be refactoring the code while they’re working on this or have changed directions on how to implement a future.
Insights into the New Dashcam Viewer
More significantly, for users on HW3, Green reported that the newly improved Dashcam Viewer isn’t just an improved version of the video viewer, but it was built from the ground up, and it’s now web-based. This technical detail explains why the updated viewer is only rolling out to AMD Ryzen vehicles and not older, Intel-based vehicles. HTML-based apps are often quicker to develop but usually require more resources to perform smoothly, which may be why we’re seeing the Ryzen infotainment system requirement.
This likely means that the new Dashcam Viewer won’t arrive on Intel vehicles in a future update unless Tesla can optimize the viewer enough to perform adequately on the older hardware.
HW3 vehicles already missed out on the new B-pillar recording feature. While Green thinks it’s technically possible to bring this feature to HW3 cars, unknown technical issues are likely preventing it. Older HW3 vehicles without a USB port in the glovebox only include USB 2 ports, limiting bandwidth, which could be one of the reasons, among others.
New Key Types
Perhaps a hint at Tesla’s third-party Robotaxi fleet ambitions, Tesla is building out new types of keys.
Rider Keys: These new keys appear to be designed to allow designated riders to access vehicles that are operating in “fleet mode.” This functionality sounds very much like what will be needed to allow Robotaxi customers to access a vehicle temporarily while they’re being given a ride.
Pre-Delivery Keys: Another new key type found is “pre-delivery.” While we don’t have an exact purpose nailed down quite yet, we’re assuming this could potentially allow new owners limited access to their vehicles for inspection prior to officially accepting delivery.
That’s plenty of interesting stuff found in the 2025 Spring Update - and we’re excited to see even more in just a few short weeks once Tesla launches their Robotaxi network in Austin.
![Tesla Updates Lane Departure Avoidance, Likely Now Using FSD Stack [Video]](https://www.notateslaapp.com/img/containers/article_images/tesla-screen/lane-departure-warning.webp/bac626b9acadf88ee44775c5ee187c06/lane-departure-warning.jpg)
![Exclusive: A Look Inside the Tesla Diner [PHOTOS]](https://www.notateslaapp.com/img/containers/article_images/2025/diner-seats.jpg/b0b4cb51b80d1f29298c9ca6b9ad2ae8/diner-seats.jpg)
_300w.png)
