Sandy Munro once again had the opportunity to chat (video below) with Lars Moravy, Tesla’s Vice President of Vehicle Engineering, as well as Franz Von Holzhausen, Tesla’s Chief of Vehicle Design. This time, rather than focusing on the improvements to the refreshed Model Y and all the new engineering behind it, the focus was on Tesla’s autonomous ambitions.
In this case, the Cybercab and Robovan were the key highlights, with a distinct focus on the Cybercab. With that all said, let’s dig into all the fun new stuff. You can check out the entire video at the end of the article.
Cybercab Unboxed Process
The Cybercab will be the first of Tesla’s vehicles to use their new unboxed assembly process, which builds vehicles in parallel sections, and then brings them together all at once for final assembly. Traditionally, vehicles are assembled from the ground up, and sometimes even disassembled for parts of production to take place.
This innovative method involves using a big rear and front casting, brought together by a structural battery pack on the floor. The door rings are hot-stamped and laser-welded to form the side shell of the Cybercab, resulting in a very rigid structure that can also absorb crash impacts due to its unique manufacturing.
Paint-Free Panels
We’ve already talked about the Cybercab’s unique paint-free panels, but we’ve never heard until now exactly how Tesla intends to manufacture them. Tesla will inject colored PU plastic onto the backside of another plastic part (formed from various processes) and then ultrasonically weld that entire piece to an inner part.
That essentially combines multiple parts into one smooth piece that is easy to repair - because all you have to do is remove the entire panel - it just comes off as the interior fasteners are removed. There is no subframe holding it together - instead, the subframe is part of the panel.
The only area of the vehicle that will have any paint will be the hot-stamped door rings - which will be painted to improve corrosion resistance to protect the steel.
Aerodynamics
Aerodynamically, the Cybercab boasts the largest aero-cover-to-wheel ratio of any Tesla vehicle. This updated aero cover improves efficiency, even with the Cybercab’s relatively large tires—chosen to reduce rolling resistance. Interestingly, the impact of unsprung weight on efficiency is minimal compared to the benefits of improved rolling resistance and aerodynamics.
Another key to the aerodynamics is the teardrop shape of the Cybercab itself. With its low profile and smooth shape, it is extremely aerodynamically efficient. While neither Sandy nor Lars delved into drag coefficients, we expect it will likely be more efficient than the Model 3’s already fantastic Cd of 0.219.
Range and Battery Pack
Tesla currently has prototypes undergoing real-world testing at Giga Texas to evaluate range and efficiency. The goal is to ensure the vehicle can operate throughout an entire day in the city before returning to charge.
Tesla is targeting a battery pack under 50kWh, delivering close to 300 miles of real-world range—an impressive efficiency of around 166Wh/mi, even outperforming the Model 3’s lowest at 181Wh/mi.
When Does It Arrive?
So, with all that new knowledge - when does the Cybercab arrive? Well - the prototypes for the June Robotaxi network deployment in Austin are getting prepared now - but Tesla expects to begin production and sales sometime in the first half of 2026.
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Sometimes, even with Tesla’s intensive bug-testing regime, bugs manage to make it out into the wild. In this particular case, a European user noticed that their 2024 Model 3 was using up more battery than normal while parked. Normally, they noted that the vehicle would lose about 1-2% per week; however, recently, they noticed much larger drops of 3-4% per night.
They monitored their Tesla widget and noticed the car wasn’t entering deep sleep. The widget consistently showed a recent connection time—usually within the past 45 minutes.
Fix Inbound
After discussing the issue with other Tesla owners and realizing it was somewhat widespread, they contacted Tesla Service. The service team confirmed that it was a firmware bug affecting the Telematics Control Unit (TCU), which prevented the vehicle from entering deep sleep mode.
The TCU is essentially the communications hub of your Tesla - and is mounted on the ceiling of newer vehicles such as the Model 3 and the new Model Y. It enables cellular and location services (via GPS) and also handles Wi-Fi and Bluetooth services. Tesla Service stated that this bug is planned to be fixed in update 2025.14.6, although the exact version number could change. However, they confirmed that they are aware of the issue and it is being addressed.
Not a Tesla App
When the user reached out to Tesla Service, Tesla Service responded with the following (translated from Dutch):
“It has been confirmed that this is a firmware bug. The fix is in one of the next updates. Currently, it is planned for 2025.14.6 (subject to change). Do you have any more questions?”
Potentially Region-Specific
This bug could potentially be region-specific. TCUs often require specific hardware components, such as modems, as well as specific firmware versions that support different regions and cellular providers. These enable Tesla to comply with local cellular standards and regulations and ensure that your vehicle can connect to the networks available in that particular region.
At this point, it’s not clear when the fix will roll out, but given that update 2025.14.1 has practically stopped rolling out, Tesla may be waiting to resume the rollout with update 2025.14.3 or this 2025.14.6 version.
If you’ve noticed this issue and are in a non-European nation, let us know.
There has been extensive reporting on what the long-anticipated affordable EV option would become, and we’ve seen numerous news stories mentioning that it was delayed or even arriving on time. The executive team revealed the near-term and long-term plans for Tesla’s upcoming vehicles, and there’s definitely good news to share here.
Updated Timeline
The most important piece of news is that despite all the talk of delays from supposed inside sources, Tesla has confirmed that the plan for its more affordable model remains on schedule for production to begin in the first half of 2025. Tesla’s executive team narrowed that timeline down further - and said that they expect production to kick off as soon as June and that the new model will be in the market shortly thereafter.
While the production timeline itself is on track, Tesla did note that the subsequent ramping process will likely be slower than initially hoped, citing global tariff and financial impacts as challenges to overcome to prepare its production lines.
Hybrid Production Approach
Tesla has once again confirmed that this will not be their next-generation vehicle, built using new production methods. Instead, they outlined a relatively more pragmatic approach for this new model.
Tesla will utilize aspects of both the next-generation platform as well as some parts of its current platforms (namely the Model 3 and Model Y). This means that Tesla will produce this new vehicle on the same manufacturing lines as the Model 3 and Model Y.
This strategy allows Tesla to bring the vehicle to the market more quickly, while also managing capital expenditures more efficiently by using existing infrastructure. However, Tesla’s executive team also noted that this approach, while faster, will result in fewer cost reductions than what might have been achieved with an entirely new platform and dedicated manufacturing process.
Vehicle Design
Using these existing production lines means that Tesla’s new vehicle will likely share some considerable similarities with either the existing Model 3 or Model Y. Rather than being a radically different and smaller vehicle, this new model will resemble the overall form factor and shape of Tesla’s current core offerings, while being optimized for a lower cost.
This doesn’t mean that Tesla is forgetting the overall goal here. Their ultimate goal is to reduce the initial cost of ownership and lower monthly payments for customers while maintaining a standard of excellence and safety.
Not Unboxed
Both at this Earnings Call and previous ones, Tesla has indicated that this new vehicle will not be using the innovative unboxed assembly method, at least for the time being. That relatively unique method will be developed and implemented specifically for the purpose-built Cybercab and for future vehicles on the next-generation platform.
We’re just a few days away from May, so it won’t be long before we see more about this upcoming vehicle. Stay tuned.
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