Tesla presents new rear structure for Model Y – Musk says, “Revolution” in production

In its update for the first quarter of 2020, Tesla not only delivered a number of mostly positive business figures, but also insights into the production of its new Model Y which is being manufactured at the Tesla main plant in Fremont since this year. In the first quarter, more Model Y had already been produced in Fremont than Model 3 in Gigafactory Shanghai.

Tesla Model Y rear underbody, 2 pieces of metal (eventually a single body)

Tesla is already profitable with Model Y

Tesla CFO Zachary Kirkhorn said that Model Y was already profitable in this early phase – something that had never been seen before with a new Tesla model. This was justified, among other things, by many similarities with the Model 3 in parts and production processes as well as the already experienced US workforce. The margin of the latest electric car was still below the Tesla average, but according to Kirkhorn: it can only be increased significantly by increasing the number of units. According to CEO Elon Musk, this is possible thanks to technical innovations even with increasing quality, for example through less weight.

A first example of this principle is illustrated in the Tesla quarterly report; Musk had already discussed this in a podcast with production consultant Sandy Munro. Unlike the Model 3 with 70 parts, which Munro has clearly criticized, the rear structure of the Model Y only consists of 2 parts and a connection between them. Tesla presents this difference in four images: two 3D images of Model 3 and Model Y with the rear part highlighted and one image of the real part of both models, supported by pallets.

Tesla Model 3 rear underbody, 70 pieces of metal

In a statement on the first quarter, Musk described the rear, which is made up of just two large cast components, as “revolutionary”. The Tesla CEO also confirmed statements from the podcast later this year that the structure will literally consist of a single cast, which will then basically make up the entire rear third of the Model Y. This advancement of technology for construction and production saves weight and reduces vibrations – “it is actually better in every respect”.

Giant die-casting machines

In the podcast, Musk had reported that Tesla had bought two huge die-casting machines. One of them is “as big as a small house”, imported from Italy, the installation should begin in May if possible. It can therefore be assumed that it will be used in Fremont, because the building for the production of the Tesla Model Y in China is still under construction (albeit at high speed).

Model 3 rear underbody, 70 pieces
Model Y rear underbody, 2 pieces
Author: Nabeel K
Email: nabeel@wheelsjoint.com


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Adison Gallagher
Adison Gallagher
2 years ago

I googled a bit. It seems to be the case that this is a rather “normal” industrial change. At least BMW or Daimler seem to be using something like that. It wouldn’t be logical if Tesla is the only one driving this change which is happening for some time now. Does anyone have an overview of how special the Tesla solution is (compared to the other automakers)? But I could imagine at Tesla that it is easier to implement because the range of car models is (comparatively) limited …

Ed Hughes
Ed Hughes
2 years ago

Composite short fiber reinforce die cost and BE on cost of die is in the 1000s of parts. For commercial aircraft die cost killed this type of mfg and even Tesla can not beat BE cost of die casting and failed parts that have to reworked via patch or welding which weaken the final structure.