Tesla continues to rely on innovative manufacturing technologies. With the new Model Y, the company has abandoned the front casting process and instead focused on optimized rear castings – a step that simplifies assembly, reduces production costs, and increases repairability. Find out here what improvements Tesla has implemented and what advantages this offers for your Model Y.
Optimization of Rear Castings
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Weight reduction and efficiency increase:
The revised rear casting now weighs about 60 kg instead of the original 67 kg – a reduction of about 7 kg, which contributes to better vehicle dynamics and an extended range. -
Faster production:
Through improved manufacturing processes, supported by in-house fluid dynamics software, the processing time per part was reduced from 180 seconds to just 75 seconds – which corresponds to a time saving of almost 60%.
Abandonment of Front Casting and Simplified Production
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Standardization and parts interchangeability:
Tesla has decided to forgo a separate front casting. Instead, a uniform body is produced worldwide to reduce the number of unique parts and simplify the supply chain. -
Phase change in battery technology:
While Giga Texas and Giga Berlin initially used structural battery packs, this solution was quickly abandoned due to the subpar performance of the first 4680 battery cell. This underscores Tesla's willingness to respond flexibly to production and technology demands.
New Casting Methods and Conformal Cooling
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Innovative technology:
Tesla has further improved the casting process by using conformal cooling methods. The die is directly cooled in the Gigapress – a method that accelerates material flow and improves the dimensional stability of the parts. -
Patented thermal control:
A new, patented thermal control unit allows precise control of the coolant flow and different cooling rates for various areas of the die. This not only optimizes the quality of the castings but also significantly reduces production effort.
Advantages and Future Prospects
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Production Speed:
With the new casting methods, a new Model Y rolls off the line every 43 seconds at Giga Berlin, Giga Texas, and Fremont – an impressive advancement in automobile production. -
Improved Repairability:
The reduction of unique parts not only simplifies production but also repairs, as replacement parts are easier to interchange. -
Future Vision:
Although Tesla currently relies on a common body design, there is the possibility of returning to front and rear casting in the future – especially when new battery technologies like structural battery packs are mature.
Conclusion
Tesla once again proves with the new Model Y that continuous innovation is the key to success. By foregoing front casting and optimizing rear casting, Tesla not only improves production processes but also vehicle performance and repairability. These advancements are further evidence of Tesla's pioneering role in automobile production.