FSD Beta V11 will be Tesla's next major FSD update
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Stop me if you’ve heard this before, but Elon Musk says Version 11 of Full Self Driving will be released in two weeks. Tesla’s CEO has promised the long-awaited FSD V11 a few times. Most observers were certain it would be part of the Holiday update, but here we are in the second week of 2023 without Version 11.
However, unprompted, Musk responded to a general tweet about Tesla and the stock price. Musk tweeted: Looks like V11.3 will be ready for wide release in about 2 weeks. Many major improvements.
Improved Highway Autopilot
This is the build that has been touted by the CEO as the big one for several months now. The big change in FSD Beta V11 will be the new highway Autopilot experience. Tesla is leveraging and adapting the neural nets they use for city driving to highway driving. Navigate on Autopilot hasn't seen many advances in the last few years, but that's expected to change with this update.
Highway driving is notably easier than city driving, but when Tesla finally merges the two tech stacks we should see several improvements to Navigate on Autopilot, including smoother lane changes, merges and better transitions when entering or exiting the highway.
FSD Beta V11.3 may also finally include Tesla's 'reverse creep' feature which has been talked about for some time. This will allow the vehicle to reverse and readjust or move out of dangerous situations.
Release Notes
The FSD V11 release notes were partially leaked in November. However, there are likely now even more improvements in V11.3. The notes for V11 stated:
Enabled FSD Beta on highway. This unifies the vision and planning stack on and off-highway and replaces the legacy highway stack, which is over four years old. The legacy highway stack still relies on several single-camera and single-frame networks, and was setup to handle simple lane-specific maneuvers. FSD Beta's multi-camera video networks and next-gen planner, that allows for more complex agent interactions with less reliance on lanes, make way for adding more intelligent behaviors, smoother control and better decision making.
Improved Occupancy Network's recall for close by obstacles and precision in severe weather conditions with a 4x increase in transformer spatial resolution, 20% increase in image featurizer capacity, improved side camera calibration, and 260k more video training clips (real-world and simulation).
It's Unknown Who Gets FSD Beta V11
It’s unclear who's getting FSD Beta V11 in two weeks. Will it include a wider range of employees, or will it go to the OG beta testers as well?
With the latest Tesla updates, it appears Tesla has finally merged FSD Beta software and production builds, meaning that FSD Beta is available to everyone in the U.S. and Canada. However, does that mean all FSD Beta users will get v11 right away? Likely not, as Tesla will probably want to roll it out slowly and release minor revisions before everyone has access to it.
What to Expect
Expectations are key. Whenever Elon Musk communicates a date, that is often the best-case scenario and delays are a real possibility.
We may see the first glimpse of FSD Beta V11 in two to three weeks, but it'll likely be in limited numbers.
We know that Tesla employees were testing V11 in November. At that time, it was believed that the program would soon roll out to a small group of public testers to get more input.
We don't know just how far into testing V11 has been. But for Musk, who has been busy with Tesla, Twitter, and SpaceX, to take the time to again give an update and a timeline for V11, the most advanced FSD yet must be coming soon. Right?
Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
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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