Cyber Rodeo Anthology Part #2: Battery Assembly and Structural Pack [multi-part series]

Cyber Rodeo Photo Credit: Tesla

Welcome to Cyber Rodeo Anthology, Part #2. Why not slow down and fix a nice snack, sit for a while and join me to understand better what goes into making a Tesla!

Part #1 of this series showed details on how Giga Texas makes front and rear castings and seats.  Part #2 is about how Tesla builds batteries into assemblies to form a structural pack to connect the front to the rear casting. Only Tesla does this, and they only do it with the Model Y so far.

The rodeo took place on April 7, 2022, at Tesla HQ on 1 Tesla Road, Austin, Texas, and showcased almost all aspects of how Elon Musk is mass-producing electric vehicles. The rodeo was unique and used colors, light, and music. Employees were available to explain different aspects of the manufacturing process.

Tesla Builds 4680 Batteries into the Structural Pack

Tesla builds 4680 batteries [left and center], which then form part of the structural pack, right. [Photo credit @GerberKawasaki]

Batteries are first built, then they are connected together in strings, as shown above, next they move to form the inner strength of the structural pack as seen above on the right. All of this work is done by robots.

Battery and Subframe Marraige

Battery and Subframe Marriage takes one simple step at Gigafactory Texas [Photo Credit @DirtyTesla ]

Tesla uses the structural pack as shown above, as the floor. They simultaneously install the front and rear subframe assemblies with the batteries, seats, and interior trimmings. This saves time, space, and resources, making assembly processes on the rest of the line more efficient and ergonomic.

Meet the 4680 Batteries

Tesla 4680 Batteries [above] have 5x greater energy capacity than other batteries. This makes manufacturing a vehicle easier for Tesla. Tesla vehicles are always getting better, and most of those differences are subtle ones from one car generation to the next. As a Tesla owner, I won’t need to be concerned about which battery type lies underneath my drive. The vehicle’s software has the capacity to come close to matching my vehicle’s function to most newer ones.

Battery assembly explained at Gigafactory Texas [Photo Credit @DirtyTesla ].

At the rodeo, Tesla explained that Battery Assembly goes from raw to ready in this way,

Made at Gigafactory Texas, our new 4680 lowers the cost per kilowatt hour. We have everything we need under one roof to produce and assemble the first high volume structural battery pack using our fully integrated process. The structural pack greatly reduces the number of parts used in both the battery pack and the car, allowing our pack manufacturing line to be less than half the size of previous factories.

TESLA

Safety is #1 for Tesla

Seats attach directly to the structural pack [Photo credit of SEATS ON PACK Sawyer Merritt].

Many things are happening at once to create a Model Y at Giga Texas. The above picture shows the seats attached directly to the structural [battery] pack.

Giga Texas Construction [Credit Tesla]

My thoughts

The more I reflect on the Tesla Cyber Rodeo experience, the more I think of the gigafactory in terms of 3D engineering. So, while one part of the Model Y is being built in one part of the gigafactory, many other parts of the same car are being built in other parts of the enormous building. In this way, the parts converge together to create Model Y. No other manufacturing system compares to this.

Thank you for reading this article, it is the 2nd in a multi-part series I am writing titled ‘Cyber Rodeo Anthology.’ I know you are here because you believe in the mission of Tesla. Thank you for your role in helping our world be a better place!

Read the rest of this three-part series here:

If you want to know more about Tesla, check out their recent feature on Giga Texas about jobs and more here. Tesla Quarter One 2022 Shareholder’s Deck is here.

Gail Alfar [edited by Sarah Alfar], Exclusive to What’s Up Tesla – April 23, 2022 –  All Rights Reserved

6 thoughts on “Cyber Rodeo Anthology Part #2: Battery Assembly and Structural Pack [multi-part series]

  1. Very well researched Gail.
    Tesla is years ahead of the other manufacturers. In such a short time, so many innovative things have been created and processes are always being improved, optimized in terms of time and costs.
    We would never have gotten this far without Elon.
    It’s fascinating to be part of this exciting time.

    Liked by 1 person

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