Tesla Megapack: How Tesla Is Reinventing Global Energy Infrastructure

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Tesla’s Megapack is rapidly becoming a key component in energy storage and grid modernization efforts worldwide. Though often associated with powering AI infrastructure or industrial operations, Megapack’s true strength lies in its ability to stabilize electrical grids during blackouts and brownouts.

In a recent behind-the-scenes reveal, Tesla showcased the impressive scale of Megapack production at its Mega Lathrop facility, along with real-world examples of how these systems are already transforming energy resilience across the globe.

Mega-Scale Megapack

Tesla is operating the largest utility-scale battery manufacturing facility in North America at Mega Lathrop, which has the capacity to produce 10,000 Megapacks annually. Thanks to a highly automated assembly process that uses over 30 welding robots to assemble the core Megapack structure. This is the largest manufacturing fixture Tesla uses— likely to only be matched by future developments at Mega Shanghai.

Tesla uses a highly automated powder coating process, utilizing over 90 robotic paint atomizers to apply more than 140 pounds of powder coat to each Megapack. This process delivers Tesla’s signature white reflective finish, engineered for long-term durability and corrosion resistance that lasts up to 20 years, even in harsh coastal or high-heat environments.

All of Megapack’s power electronics are designed and built in-house. Each Megapack uses 24 battery modules, electrical busing, and thermal management systems to ensure grid reliability and help to maximize energy density. The architecture pairs each inverter with a battery module to maximize energy availability and overall uptime. Plus, before each Megapack ships its way across the world, Tesla performs rigorous on-site quality control to ensure that the installation process is as seamless as possible.

Watch Tesla’s video of the manufacturing process below:

Megapack’s Real-World Impact: Hawaii

The core purpose of Megapack is to make power grids more stable and resilient while also reducing reliance on dirty peak power plants like coal. They achieve this by balancing energy supply and demand in real-time, smoothing out fluctuations from variable renewable sources like solar and wind, which helps to prevent grid shortages.

Hawaii actually provides the most real and down-to-earth example of Megapack’s impact. In mid-2024, the Kapolei Energy Storage facility in Hawaii came online. Hawaii utilized 258 Megapacks with a combined capacity of 565 MWh, successfully replacing the state’s last coal-fired power plant. This single facility can power approximately 20% of Oahu’s peak electricity needs by itself for approximately 4 hours.

The project is more than just removing coal plants, though. It serves as an example of Megapack’s grid integration and grid forming technology. The Kapolei Energy Storage facility can manage grid fluctuations caused by weather changes impacting renewable energy, improving stability and preventing blackouts. Thanks to their rapid inverter response times of under a millisecond, Megapacks participate in complex grid balancing activities, including fast frequency and voltage support, which helps to maintain grid balance throughout the day. Beyond that, Kapolei also allows Hawaii to black-start the grid in case of a major power outage that takes out a large section of the grid.

This functionality would be especially useful in Spain, where black-starting the grid took over eight hours recently and is still disrupting the day-to-day life of people there.

You can check out Megapack’s real-world impact in this video from Tesla below:

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Tesla Update 2025.20 Tear Down Reveals Grok Personalities and Icons

@greentheonly on X

While most automakers are adding basic and un-integrated AI assistants to their vehicles, Tesla appears to be working hand-in-hand with xAI to build out an entire cast of characters for in-vehicle Grok. In the latest dive into Tesla’s firmware, Tesla hacker @greentheonly uncovered a few new details about the upcoming Grok feature.

This discovery, part of a larger batch of changes found in Tesla update 2025.20, also offers a hint at the hardware required for the Grok.

A Dozen Groks

While we knew from previous firmware teardowns that Tesla was adding various Grok personalities to the vehicle UI, this update introduces a new one called Language Tutor, which may allow users to learn and practice a new language. 

These are the different personas that will be included in Grok:

• Argumentative

• Assistant

• Conspiracy

• Doctor

• Kids’ Stories

• Kids’ Trivia Games

• Meditation

• Motivation

• Romantic

• Sexy

• Storyteller

• Therapist

• Language Tutor

• and the Grok Classic - Unhinged Mode

Release Date

Icons for these personalities have been added to the firmware for the first time, leading us to think Tesla is getting close to releasing the feature. However, even after the feature is developed and included in vehicle software, Tesla may only enable it selectively — such as for select employees for testing.

Grok is expected to be one of the largest vehicle features added via a software update, so it’ll be a big deal when it’s finally released. While we know more or less what to expect from Grok, what we don’t know is about vehicle requirements or whether it’ll require a subscription beyond Premium Connectivity.

Grok Requirements

While subscriptions required are anyone’s guess, vehicle requirements may be a little clearer now, thanks to Green’s discovery that Grok is only being added to AMD-based vehicle software builds.

Unfortunately, this likely means that older, Intel-based vehicles will not receive Grok support, at least for the time being. When Tesla introduced a voice assistant in China, they also started off with AMD-only support but later added Intel support, so it’s possible that the same could happen with Grok.

Energy Saving

Green also found a new undocumented navigation feature in 2025.20.3. This one focuses on leveraging Tesla’s vast amounts of data in an interesting way and offers drivers proactive advice to save energy on a well-traveled route. 

In the Energy App, your vehicle will display, “This route is typically driven at X mph. Slow down by Y mph to save Z% for the rest of this trip.’ 

As you can see in the photo below, Tesla recognizes that vehicles typically drive at 66 mph on the route being driven and offers the driver the option to go five mph slower to save 1% of range. While this example doesn’t provide much incentive to slow down, it could be useful for someone with a low state of charge or if the savings are more significant.

The new line in the Energy App

Not a Tesla App

In the future, Tesla could even use this, alongside the road surface data they’re gathering, to help plan routes for Robotaxi and Unsupervised FSD.

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NHTSA to Streamline Approvals for Control-Free Vehicles Like Tesla’s Cybercab

Not a Tesla App

In a letter to industry, the National Highway Traffic Safety Administration (NHTSA) has announced that it is overhauling its approvals process for vehicles designed without human controls.

The change addresses a regulatory bottleneck that has slowed down American companies like Tesla from deploying purpose-built Robotaxis, rather than relying on using traditional vehicles with steering wheels and pedals. The policy shift is outlined in a letter posted to the NHTSA’s website, which you can find here.

Reducing Approvals From Years to Months

Under the existing rules today, any vehicle that is built without a steering wheel or brake pedals must receive a special exemption from federal safety standards.

Obtaining exemptions for a particular vehicle was a time-consuming process for both the companies requesting exemptions and the NHTSA. The process was often a black box—nobody knew when an exemption might be granted, and approvals could take years.

The NHTSA, under the new administration’s guidelines for autonomous vehicle development, is now committed to streamlining this process. The agency will be implementing a new, faster approach immediately for receiving exemptions for autonomous vehicles without standard controls. The NHTSA expects decisions on exemption requests to be determined within months rather than years. 

Accelerating the Cybercab

This change has massive implications for Tesla, which is banking on the production of the simplified and easy-to-maintain purpose-built Cybercab. The Cybercab is developed from the ground up as an autonomous Robotaxi and will be one of the key beneficiaries of this move by the NHTSA.

Knowing that a final design won't be caught in a multi-year regulatory limbo provides a level of certainty that has been missing. It allows Tesla to confidently plan the manufacturing, development, and deployment processes without worrying whether the project will get stuck in regulatory approvals.

According to the letter, the agency will publish its improved instructions for the streamlined process "shortly." With Tesla already having begun Cybercab pre-production and the goals for its deployment as soon as late 2026, there’s still a lot to be done to make autonomy a part of Tesla’s new sustainable abundance mission statement.

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