Tesla Model Y teardown reveals beautiful megacasting manufacturing breakthrough

The Tesla Model Y teardown is starting to reveal the beautiful mega casting on the rear of the electricSUV, which could be a great manufacturing breakthrough.

As we previously reported, Sandy Munro, a manufacturing expertwho rose to fame in the Tesla community after his breakdown ofan early Model 3, is doing the Crst teardown of a Model Y.

Munro is doing relating details about the teardown piece by piece,and you can check our previous reports for Tesla Model Y’s ,t and,nish, frunk, and suspension and wiring and body casting.

The manufacturing expert is now digging deeper into the casting ofthe back end of the Model Y’s body because it features one of thegreatest improvements over the Model 3.

Here’s his latest video about what he now calls Tesla’s “mega casting”:

As we previously reported, Tesla has been working on a revolutionary new wiring architecture to helprobots build upcoming cars like the Model Y.

CEO Elon Musk also said that Tesla is moving to an aluminum casting design instead of a series ofstamped steel and aluminum pieces for the Model Y body:

When we get the big casting machine, it’ll go from 70 parts to 1 with a signi9cant reductionin capital expenditure on all the robots to put those parts together.

A new patent application Cled last year revealed this new casting machine that Tesla is using to buildModel Y.

In the new look at the casting, Munro notes some very interesting features, like the recess to protectthe brake line:

On the bottom right of that picture, you can also see a weird part of the casting sticking out. That’sactually the support for the suspension’s springs that Tesla built into the giant casting of the rear ofthe vehicle:

Munro noted that he has seen other car companies do that, but never on a casting part that big.

The manufacturing expert also said that Musk conCrmed that the already huge casting part is goingto be bigger as they are going to combined the two main parts that make the rear of the Model Y intoone giant part:

Tesla has ordered the world’s biggest casting machines in order to build those parts.

They are as big as a house and weigh 5,500 tons:

Overall, Munro was really impressed by Tesla’s work on the casting of the Model Y, though he did notesome potential improvement, especially when it comes to Oashes resulting from the welding.

He also noted some parts of the rear casting that are not used and he speculated that it might be foran air suspension retroCt:

We have seen a lot of evidence leading to Tesla planning an air suspension for Model 3 and ModelY, but Musk insists that it’s not in the plans, and Tesla will only produce air suspensions for Model S,Model X, and Cybertruck.

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Jason Bratton • 3 days ago

•

Love this series and the insights he shares. Been great entertainment during the lockdown. We got a new LR AWD Y this week and inno time feel it's the best vehicle we've ever owned. Quiet (heat pump noise is WAY overblown in videos), easy to get in and out of,stable on the road, and Tesla Fast. No rattles, no quality issues that we've noticed, and looks fantastic. An improved Model 3 with ahatch is what we wanted, and Tesla delivered as we had hoped! They are going to sell millions when the economy gets right side up.

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Kay • 3 days ago

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> Jason Bratton

Congrats on the new Y! Might I ask what interior / exterior colors you selected and your location? My wife's eagerly awaitinghers!

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Jason Bratton • 3 days ago

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> Kay

Thanks! We got Red w/ black interior and the 20" Black induction wheels. We hit the waive of cancels as we ordered itin March and had a VIN in less than 3 weeks. We are out of OKC and they delivered to the house in their touch freeprocess. Easy peasy. Good luck!

10△ ▽

Anozie Kelechi Udemezue • 2 days ago • edited

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> Jason Bratton

Do you also have a Model 3? Congratulations on your new Tesla Model Y, btw!△ ▽

Pikminiman • 3 days ago

•I'm running out of ways to express how much I enjoy watching this series.

29△ ▽ 1

Kevin Deschênes • 3 days ago

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> Pikminiman

I laughed so hard in the glass episode! I didn't thought this guy could both be knowledgeable and entertaining 4△ ▽

Preston Crow • 3 days ago

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There is a lot of evidence that Tesla is designing air suspension for the 3/Y, while Elon keeps denying that it's in the plans. These arenot contradictions. Clearly they're doing the engineering to have air suspension as an option, but the business side has no plans torelease that option. So the plan is for now air suspension until they change their mind, and then they'll have it immediately.

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RayzorBEV • 3 days ago

•It's so cool to see so much progress going from just the Model 3 to Y. I'm impressed...

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AntiochOG • 3 days ago • edited

•

What are the implications of using large cast pieces compared to traditional manufacturing techniques when it comes to the cost ofcollision repairs? Can we expect Tesla vehicles to be totaled when a traditionally manufactured vehicle would be repaired, or viceversa? It's my understanding that the expensive sensor suite used by Tesla results in more totaled vehicles already.

This could have an effect on the costs to insure Teslas, but could also mean more 2nd hand Tesla batteries and motors available forretrofits into existing ICE classics.

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jelloslug • 3 days ago

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> AntiochOG

My opinion on this is that if the crash is severe enough to damage the casting, it probably totaled the car anyway. 11△ ▽

ITFA • 2 days ago

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> jelloslug

Crashes that damage the frame/chassis under a front quarter panel are not the least bit unusual, and are usuallyrelatively simple to repair. Looking at the images in their patent filing, that kind of casting would absolutely take damageduring a similar crash that wouldn't total any traditional modern vehicle.

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Brandon Fortino • 2 days ago

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> ITFA

There are replaceable crash bars in the back (and maybe the front)? The idea being you replace the crash barsfor minor fender benders that do hit hard enough to damage the chassis of a conventional car. Anything thatbends the crash bar and frame is going to likely be a vehicle loss event.△ ▽

jelloslug • 2 days ago

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> ITFA

The casting is in the rear of the car.△ ▽

ITFA • 2 days ago

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> jelloslug

Yeah, notice I referenced the imaging in their patent application? IF they get that big...△ ▽

Tallyaman • 3 days ago

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> AntiochOG

Reasonable question. However this will be the direction new vehicle manufacture will be heading. Insurance companies mightfind it advantageous as it simplify the accident costing and replacement.

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Nick • 3 days ago

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> Tallyaman

Doesn't seem very sustainable though to just purchase a new one every time. 4△ ▽

William Naughton • 3 days ago

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> Nick

You take a junker, cut out the section you need, cut the bent part, weld the "new" one. Pretty much as you woulddo with any unibody section. Heard that aluminum is harder to work with than steel though.... so it'll costsomewhat more.

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asg21 • 2 days ago

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> William Naughton

I had no idea Trump U offered degrees in automobile manufacturing!△ ▽ 2

Mitt Zombie • a day ago

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> asg21

Elon was telling people to take the aquarium cleaner too,△ ▽

Michael Rogers • 3 days ago • edited

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> Nick

Definitely not eco friendly to total a car for "minor" damage. At least the batteries will most likely find new life insomeone's homemade powerwalls (or my kids hopped up powerwheel)

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Nick • 3 days ago

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> Michael Rogers

Haha, that'd be quite the powerwheel!△ ▽

Michael Rogers • 3 days ago

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> Nick

Depends on how it's wired. Usually just pull out about 14 18650 cells for each powerwheel.

Still quicker than normal but not as fast as a real Tesla. 1△ ▽

PaulScott58 • 3 days ago

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> Nick

Hopefully, improvements to AV tech will reduce crashes enough to make this a non-issue. 3△ ▽

craigiri • 3 days ago

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> Nick

It could be - considering that just the deployment of air bags these days often totals a vehicle. If manufacturingand recycling techniques advance enough, it would be preferable to either replace a total car or replace largeparts (as opposed to hacking them back together at a body shop)....

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AntiochOG • 3 days ago

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> Nick

I agree Nick. Hopefully PaulScott58 is correct and crash rates are reduced enough it doesn't matter.

It is possible that if that is reduces labor enough, and recycling rates are high enough it could be more efficientto replace rather than repair, but that seems unlikely to me.

1△ ▽

Null66 • 3 days ago

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> AntiochOG

If a crash goes that deep into a car it should be totalled. You don't want it back.

Been there with a Contour Se v6... bent in the middle everytime you shifted. It was a great car until the semi hit it. But I did getout of it ok. So all in all I really can't complain.

5△ ▽

Will Meek • 3 days ago

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> AntiochOG

A wreck severe enough to damage this casting would total any other car anyway so no impact on repairability or insurance. 4△ ▽ 1

William Naughton • 3 days ago

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> AntiochOG

Bolted pieces could be replaced but they are a source of squeaks as well. Movement is to unibody of welded pieces. Withlarge cast pieces, spare parts are cut from larger pieces and welded in place. So, whether you weld two pieces or it is alreadyone piece, the solution of a bent frame section remains to cut it out and weld back an unbent section (whether cut from a largerpiece or supplied as an independant piece. - in short, its not much harder to repair. Bolted is another story (much easier) butalso has issues.

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Ben Blackburn • 3 days ago

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> William Naughton

Welding on a broken aluminum casting is not usually very good.It makes bad internal stresses and messes up the metallurgy of the metal, so it will never be strong again, so I don'tthink that it will be repairable, at least not with any safety.

Also, in order to weld two pieces of cast metal together, you have to bevel the ends so that you start welding in themiddle, and then refill the entire bevel section one weld bead at a time, so it's very labor intensive and time consumingunlike welding sheet metal.So really it's cheaper just to swap a new cast piece in then to spend hours welding and heat treating a broken one,which will never be as strong as a new one.

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craigiri • 3 days ago

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> Ben Blackburn

Welding a die cast part, as you suggest, if unlikely to be in the cards. The entire deal depends on the "oneness"of the original casting. This may differ with less structural items such as doors or floors, etc.△ ▽

traumadog • 2 days ago

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> AntiochOG

I do wonder how well collision repair is a factor here.

Watched a Rich Rebuilds YouTube episode recently, and (besides noting how a blacklisted Tesla can't even DC fast chargealong with not being able to Supercharge) he saw a Model X 70 in a junkyard, with what appeared to be relatively minor driverrear quarter damage. The rear bumper was missing, but everything else was intact.

Odd that a car with such visibly minor damage was considered totalled. 1△ ▽

ITFA • 2 days ago

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> AntiochOG

I was wondering that myself. That patent image shows a "mega casting" that could never be repaired to near-new status in acrash that would normally cost a few thousand dollars to repair something like a corolla. If they legitimately get to be that largean intricate, are we just expected to write off a $50k car after a 15 MPH bump?

1△ ▽

Fossan Gjengen • 2 days ago

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> AntiochOG

Putting Tesla parts into classics is nothing else than pure blasphemy.. :(△ ▽

GreenPat • 3 days ago

•

Great mix of content. Great visuals and descriptions. Great way to view some amazing engineering.

So glad he doesn’t hold back on critiques. Like the weld wiskers. As soon as Elon see this that’s fixed if it’s not already. That’s a 100%manufacturing floor issue not engineering. And 100% fixable.

Tesla moves so fast. The continuous improvement of platforms is as important as the initial designs. I’m guessing Model Y productionin Shanghai launches Q3, deliveries Q4. Plus it will have a number of recently discussed updates already implemented. Don’t besurprised if there is a Model Y SR base starting just under the new 300,000 Yuan cut off for subsidies China just implemented. ModelY will become a top seller in China. Overall, not just EVs.

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craigiri • 3 days ago

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Having been in some business that used castings, I am fascinated by the technology - I can sit around for hours and watch videos ofcasting tech. I was lucky enough to take some tours of casting plants in PA and VT. Perhaps the most amazing thing is that as thetechnology has advanced, there are fewer and fewer people on the factory floor. The productivity is so high that many of the modernmachines have a hard time finding enough work to keep them going. I'm lusting for a Y - and likely will have one as I want to be safer driving as I get older.

4△ ▽

Rod Bowler • 2 days ago

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> craigiri

Did you hear Elon's description of the casting technique on the Third Row Tesla podcast? I think you'd like it. Injection of themolten alloy in 40ms!

2△ ▽

Gerbera Maqiti • 2 days ago

•

The Electrek report confuses two issues:1) a visible flash line on the rear casting caused by minute amounts of alloy flowing between two neighbouring parts of the die(irrelevant)2) welding flash on the steel inner sill / rocker assemblies running along the sides of the vehicle (of which Sandy was critical).

2△ ▽

Andrew Doolittle • a day ago

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> Gerbera Maqiti

Casting and *combining through pressure*(stamping) are 2 different processes I would agree.

When I think of casting I think of metal poured through a mold. I don't really see the value in casting metal over stamping metalin a Das Auto in the first place.△ ▽

Gerbera Maqiti • a day ago

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> Andrew Doolittle

Let me clarify: Tesla uses high pressure injection casting using a special alloy that allows good flow when molten. It's nolonger the 17th century! In effect it's like plastic injection molding, only using aluminum alloy. This is ultra fast and thepiece cost is low. The injection mold is made from several very heavy sections that are bolted together, hence the flashline.△ ▽

Nick • 3 days ago

•

Is there a down side to this? I'm just curious about repairability and how that would work. I assume this makes the vehicle lessexpensive to build, less parts, and thus more reliability - all great things, only negative I would think would be on repairs.

2△ ▽

Michael B • 3 days ago

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> Nick

It costs more to setup but costs less per part. I can't speak to these parts in particular, but in general, cast parts are alsostronger than stamped parts (for equivalent size and weight), but when they do fail, it's catastrophic (they shatter instead ofbending). I don't think these parts are likely to be repaired, as they are very internal and structural. The car is basically totaled ifthese need repair.

5△ ▽ 1

GreenPat • 3 days ago

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> Nick

If there has been enough damage that this large casting is effected, then that vehicle EV or ICE would be totaled underinsurance.

Any repairs would be to a salvage title vehicle. With well designed BEVs it’s better to salvage battery, powertrain, and other keysystems then recycle the rest.△ ▽

DanFrederiksen • 3 days ago • edited

•

Interesting. I wonder though if a simple HSS tube structure wouldn't be vastly superior. Not only are tubes and triangle latticestructures quite strong but if there is a workable steel at aermet100 strength, it's hard to imagine it would weigh anything at all. Withoptimization like that I see no reason why a Model 3 couldn't be under a ton. Can't help think that could be a lethal margin advantage.Why win at great hardship if you can win far more in comfort.

1△ ▽

Gerbera Maqiti • a day ago

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> DanFrederiksen

Assembly costs would be prohibitive, as each tube needs welding in place on a jig. Tesla is looking for eventual fully automated"no human" (or minimal humans) production, and frame casting is a big step towards this. To replace 70 pieces with 2(eventually 1) is phenomenal value engineering. It saves in time, reduces robots and production area, and increases quality.△ ▽

DanFrederiksen • a day ago

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> Gerbera Maqiti

I don't believe that is true. Cutting, placing and welding tube is a nicely light and uniform process that can be done withinexpensive robots. A high performance steel might need to be heat treated though but doubling strength/halvingweight could be well worth it.△ ▽

hymnoptera • a day ago

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> DanFrederiksen

Good to see you are no longer harping on fiberglass.△ ▽

DanFrederiksen • a day ago

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> hymnoptera

fiberglass is widely used in planes and yachts, quite a high performance material where suitable. Less obvious forskinny rigidity and can be more labor intensive. And Aermet100 is not your average steel.△ ▽

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Fred Lambert - Apr. 24th 2020 1:22 pm ET @FredericLambert

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