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.
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According to a new report from Business Insider, Tesla is planning a week-long production pause for the Cybertruck and Model Y lines at Giga Texas. On the surface, the reason seems pretty straightforward: maintenance and line upgrades.
But Tesla has been infamous for never shutting down lines unless it's an absolute production necessity. Given that this is the third production pause in the last 12 months, this suggests that Tesla is planning something other than routine maintenance.
Official Story
The facts, as reported by BI, are fairly straightforward. Tesla will be shutting down the Model Y and Cybertruck lines from June 30th to July 4th. In a staff meeting at Giga Texas, Tesla stated that the pause would enable maintenance and upgrades to help ramp up production.
While this could seem odd for the recently updated Model Y and Cybertruck lines, it also makes sense as Tesla continuously makes production improvements, rather than waiting for model year updates.
There definitely feels like there’s more to this story than a simple pause, but the timing and context suggest this pause is far more significant.
The Affordable Model
The key to this shutdown is Tesla’s strategy for its more affordable model. Tesla has pivoted away from building Giga Mexico, and is instead planning to build both the Cybercab with its unboxed assembly process, as well as the next-gen affordable vehicle at Giga Texas.
For now, Tesla plans to build the affordable model based on existing production lines within Giga Texas, rather than build a standalone line. This is mostly because Tesla intends for the affordable model to have a high part familiarity with the Model 3 and Model Y.
The Model Y line, in particular, is the prime candidate for this retooling. It is Tesla's most refined high-volume production line, and the tooling and equipment on the line are perfectly suited to enable Tesla’s quick transition to producing the new model.
A week-long shutdown is not enough time for a complete overhaul, but it is the perfect window to begin preparatory work. This could include installing new mounting points for future robotics, rerouting utilities, or even running initial trials for new assembly processes in a portion of the line.
Timing is Everything
This theory makes even more sense in the context of recent events. The cheaper model was initially planned for the first half of 2025, but following reported delays, the timing seems right for Tesla to start incorporating changes to support the new vehicle. While Tesla initially planned for a cheaper model to be based on the Cybercab with its unboxed assembly, they decided to produce one based on the current assembly line to get to market sooner. This isn’t the cheaper, “$25k” vehicle we were all hoping for, but instead a more affordable version of the Model 3 or Model Y.
While the Cybertruck line is likely undergoing standard ramp-up tweaks, the shutdown of the Model Y line likely presents something more. While it could also include maintenance and incorporate updated tools, it may include changes required for the newer model.
More Than Maintenance
While the official reason reported by Business Insider seems fairly plausible, there’s always more under the surface when it comes to major decisions like this with Tesla. Using the planned maintenance window to quietly begin the process of retooling is the kind of move we expect from Tesla.
Just days before Tesla’s planned launch of the Robotaxi network in Austin, a group of local lawmakers has sent a letter to Tesla, urging them to delay the launch. Citing a new state law set to take effect on September 1st, the letter asks Tesla to pause its launch until it can formally comply with the new framework.
On the surface, this could sound like a significant roadblock. However, upon closer examination of the lawmaker’s concerns, the requirements of the new law, and the upcoming unified federal autonomy regulations, the request may be more political theater than a genuine obstacle.
In fact, Tesla’s Robotaxi service appears to already meet the spirit—and likely the letter—of the upcoming regulatory framework.
The Letter and the Law
The letter, penned by State Senator Sarah Eckhardt, formally requests that Tesla postpone its planned Robotaxi launch this month until the new and more comprehensive autonomous vehicle law is in effect on September 1st. It's important to note that this isn’t a legal injunction; it doesn’t have any power, and Tesla is under no obligation to comply or even reply. The letter is a formal request, a piece of political pressure intended to encourage proactive compliance.
So, what does this new law demand? It has five key requirements for autonomous vehicle operation in Texas.
Barely A Speed Bump
A detailed look reveals that Tesla's existing technology and practices likely already meet every single requirement of the upcoming regulations, so let’s dive in.
1) Capable of operating in compliance with state traffic laws.
This is the fundamental purpose of FSD - complying with traffic laws to get a passenger from Point A to Point B. The system is designed to adhere to traffic laws, and in fact, sometimes sticks to them too closely (like the NHTSA stop).
2) Equipped with a recording device.
This is probably the easiest requirement when you look at a Tesla. Every vehicle is a rolling 360-degree security suite, equipped with multiple cameras and internal sensors that document every action taken by the vehicle.
3) Compliant with federal law, including federal motor vehicle safety standards.
Tesla is currently deploying Model Ys for its Robotaxi network pilot, which means that they are fully compliant with FMVSS standards. This will likely change once Cybercab begins to deploy, but the NHTSA is working on accelerating federal regulation for vehicles without driver controls in the near future.
4) Capable of achieving a “minimal risk condition” if the automated system is rendered inoperable.
When the system detects a critical fault or issue it cannot handle, it must slow down, activate hazard lights, and pull over to a safe location at the side of the road. That is very doable, and likely within Tesla’s calculations for how they will handle system aborts and other incidents. In fact, the Model Y robotaxis with a safety driver in the passenger seat have been spotted with buttons on the screen that say “Emergency Stop” and “Pullover.”
5) Registered, Titled, and Insured under Texas law.
This is a bog-standard requirement. Every vehicle operator must meet those three requirements, and as Tesla’s Model Ys currently driving the roads in Austin are sporting manufacturer plates, this is likely already done.
While these Texas lawmakers are asking for a pause, the NHTSA is actively working to make it easier for companies like Tesla to deploy autonomous vehicles. This state-level scrutiny, while perhaps well-intentioned, is a clear example of the challenge of deploying a national network under fragmented regulations.
Ultimately, this letter is unlikely to be anything more than a political statement. It will be logged and acknowledged, but it presents no new technical or legal hurdles for Tesla to clear before its planned launch. For an autonomous future, this isn't even a bump in the road.
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