In the past, Tesla confidently proclaimed that it would build a Model Y with one single casted part to simplify the rear body's structure. However, the latest evidence shows that its Texas factory's Model Y production line might be prepared to use single casted parts for both the front and rear parts of the vehicle.
Back in 2020, Tesla CEO Elon Musk already talked about using innovative methods for building cars. With one mega-casted part, Tesla can replace 70+ pieces of metal for the rear body. This giant part is designed in a new battery cell structure. It can reduce weight and noise. More importantly, it can avoid assembly mistakes and massively simplify multiple processes of manufacturing.
In order to achieve this goal, the automaker acquired the largest casting machines globally that already existed in the California and Shanghai Gigafactories. As far as we know, there are currently no major defects in these machines.
In Tesla's 2nd quarter financial report for 2021, there was a picture of a certain manufacturing process at Gigafactory Texas that attracted a former Tesla worker's attention. He pointed out that the Model Y vehicle in the picture not only uses a single casted part for the rear body, but also for the front body.
Let's say that this inference is correct. It would make Tesla a major game changer in the field of car engineering. More importantly, this method can save factory space, reduce steps of assembly, lower the body weight, decrease the cost of production line maintenance, and simplify the management of the supply chain. The new body engineering method will also benefit consumers because it can potentially improve the Model Y's driving range, lower its cost, and offer elbow room for price reduction.
Buying the largest casting machines doesn't necessarily mean that one can imitate Tesla's new manufacturing process. The SpaceX team's unique alloy technologies and related know-how would be hard to replicate for other automakers. When the new 4680 battery cells successfully enter the mass production phase, and the new giant casted front and rear parts are applied, the Model Y’s competitiveness will be strengthened.
Unfortunately, single-casted parts do have a huge disadvantage when it comes to repair services and maintenance. Whenever a car is involved in an accident, an auto repair shop will always need to evaluate each part's damage level and then suggest whether to replace them or not. However, if there is only one giant casted metal part that is twisted and deformed by the impact of an accident, how would the auto shops evaluate and repair it?
If we were to think like Musk and applied his favorite "first principle thinking” to the above scenario, the most critical issue that would be addressed first is probably not how we can "repair" the car. Rather, it would be how we can “solve” the root causes of car accidents. Let's say that all future cars have Level 5 autonomous self-driving capability. If that were the case, then there would probably be no more car accidents in the world. So naturally, we would not need to repair accident-related damages. However, before this dream can come true, the owners of the Model Y should still try to drive more carefully.
(Photo credit: Tesla)