Tesla Structural Battery Pack, the good and the bad

Back in September of last year, Tesla had its Battery Day presentation (full video below). In January of this year, Electrek wrote an article about the Tesla structural battery. So why am I writing about this now? The structural battery pack was just a gleam in Elon Musk’s eye at that time, but soon, there will be cars that incorporate the new design. Here’s what you should think about if you’re considering buying a Model S Plaid or a Cybertruck with the structural battery pack.

As Elon said during the presentation, the structural battery pack was inspired by the airline industry. They used to put gas tanks in the wings of airliners. The tanks added weight. More weight meant more fuel needed to fly. Eventually, the aircraft manufacturers figured out that they could save weight if the wings were the gas tanks. They saved weight that way. It’s the same with battery packs. Right now, there are battery cells that are put together in modules. The modules add weight. Then the modules are put together into a large battery pack. That adds more weight. Then all that stuff is put into the structure. More weight means less range.

Tesla engineers figured out that they could save lots of weight if they eliminated modules and if the battery pack was the structure. They do that by making a honeycomb structure with all the wiring and cooling coils inside it. Then they drop in the 4680 cells and epoxy them to the honeycomb structure. For those of you who are not aware, the designation, 4680 refers to the 46mm diameter of the battery cells and the 80mm height of the Tesla cells. Those battery cells are larger than the ones currently in use by all previously made Teslas so they store more power in each cell. For comparison, visualize the current Tesla battery cells being like AA batteries and the 4680 cells being like D batteries. Remember D batteries?

The following picture is from the article in Electrek cited above. You can appreciate the honeycomb pattern of the pack, a structure known for strength and light weight. The coolant loops are built into the sides of the pack.

So saving weight, stronger cells, less of them. More battery, less other stuff. It’s all good, right? Maybe.

Here’s the bad part.

If the car gets in an accident and the battery pack is breached, you can’t just take out the old pack and drop in another pack. That might not matter because chances are pretty good that an accident bad enough to damage the battery pack will total the car. From an individual’s perspective, that’s why you get insurance. But there are other considerations if you care about the environment you’re leaving to my grandchildren.

Batteries should be recycled. So far, they’re not designed for recycling. With technology at its current state, it’s cheaper to mine new materials than it is to recycle the materials from used batteries. The ability to recycle gets worse when the batteries are epoxied into a big honeycomb structure. I’m not a chemical engineer so I can’t offer any suggestions about how battery cells could be designed to make recycling cheaper than mining new materials, but they should be designed that way.

The other bad thing about the structural battery pack is that cells don’t all deteriorate at the same rate. With the current battery packs, bad cells can be detected and switched out for good cells to rejuvenate the range of an old Tesla. That won’t be feasible with the structural battery pack. That may or may not be important. It depends on whether the cells last as long as the rest of the car or not. Time will tell, but it’s something to think about if you plan to keep your car for the million miles that Tesla claims their cars are designed to last.

Here is Tesla's 'Battery Day' presentation. If you care exclusively about the structural battery, you can jump to the 1 hour, 19 minute mark.

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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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