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 Expected to Offer FSD Transfers in Europe

Not a Tesla App

It has been a long wait for FSD for European customers, many of whom paid for the feature years ago on now legacy hardware. While the FSD transfer program has come and gone multiple times, there’s something to be said about having it available in North America, where it can be used, and in Europe or other countries, where it still just remains the same as Enhanced Autopilot (differences between Autopilot, EAP, and FSD).

FSD Transfer is a nice goodwill gesture from Tesla that in theory doesn’t cost them anything. Instead, it keeps customers, especially those who have been waiting for years, loyal and happy. It also incentivizes them to upgrade to a newer Tesla with HW4, where FSD will hopefully be achieved.

In a reply to a post on X, Elon agreed with the suggestion that offering FSD transfers in Europe would be a fair solution for those who have already purchased FSD but can’t use its capabilities.

Sounds fair

— Elon Musk (@elonmusk) July 13, 2025

A Fair Solution

FSD Transfer directly addresses a growing concern for many long-term European Tesla owners. Thousands of customers purchased the full package, often many years ago, with the expectation that FSD would eventually be capable and approved for use. However, the reality is that FSD, even as an advanced driver assistance system (ADAS), continues to be pushed back in Europe.

As the regulatory process continues at a snail's pace, many of these early supporters are now reaching or have already passed the point where they’re ready to upgrade to a new Tesla.

Without the transfer program, it's a difficult choice: either throw away your original investment in FSD and pay for the package a second time (FSD price history), or subscribe to it in the future.

Offering FSD transfers is a good way for Tesla to meet them halfway. It's a difficult situation, and one that’s being hindered by processes beyond the control of both the customer and Tesla. However, a transfer helps both parties. Tesla sells another vehicle, and the customer gets to keep FSD.

When Will it Be Available?

Based on how FSD transfers have worked in the past following Elon’s announcements, this feature is likely to become available for a limited time period in the coming days or weeks. If it happens, we should expect an announcement from Tesla Europe on X and emails being sent out to Tesla customers.

Once the program is in place, all you need to do is complete your vehicle purchase and then inform your Tesla sales advisor that you’d like to transfer FSD. You don’t even have to sell or trade in your old Tesla; FSD will simply be removed from it as a feature.

Hopefully, Tesla enables FSD Transfers for everyone, regardless of region. It should be an ongoing offer until at least FSD is approved in the given country or region.

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Tesla Increases Robotaxi Fare Fee, Up from $4.20

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The introductory price for Tesla’s Robotaxi Network has finally been updated. In a post on X, Elon Musk confirmed that the new fare would be rolling out to complement the new Robotaxi geofence expansion.

This change marks the first adjustment to Tesla’s fares since the initial $4.20 launch price 23 days ago. While the price increase may seem significant in terms of percentages, when compared to other options in the ride-hailing area, it is still drastically cheaper.

But the price is now a princely $6.90, as foretold in the prophecy 😂

— Elon Musk (@elonmusk) July 14, 2025

Context Matters

Robotaxi currently operates on a simple, flat-rate model. The new $6.90 fare gets you a ride to anywhere within the recently expanded geofence.

So far, this is the opposite approach compared to other services, such as Waymo or traditional ride-sharing options like Uber and Lyft. All these services use dynamic pricing based on distance, time of day, and demand. A comparable trip on any one of these services could cost anywhere from $30 to $65, and potentially even higher during peak hours.

That doesn’t even include the tip fees for human drivers either - another win for Robotaxi (can you tip a Robotaxi?).

Even with the adjustment, the flat $6.90 fare remains less than half the price of a typical competing ride, making Robotaxi the most affordable point-to-point transportation option in Austin, aside from mass transit, for now.

A “Maturing” Service

The price change, moving from one meme-worthy number to another, is a sign that Robotaxi is finally graduating from its initial pilot phase. Following the first major expansion of the service area, this adjustment is a logical next step towards finding a more sustainable flat price.

While the new fare is a 65% increase over the old fare, the key takeaway is that it is still far cheaper than other options, and still just as meme-worthy. Tesla is aiming to have its early access riders complete as many rides as possible during these early months, and this pricing is still very reflective of that.

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