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Elon Musk Says Refreshed Tesla Model Y ‘Will Be Most Advanced With 2/3 Of Body Cast’

Elon Musk has confirmed the refreshed Model Y, which will be produced at Giga Texas, and Giga Berlin will have two-thirds of its body made with a Giga Press.


Tesla is currently in the final stages of bringing a refreshed Model Y to production. The vehicle when it begins production is expected to incorporate Tesla’s newest advancements announced at the company's Battery Day event.

In a previous article based on Elon Musk’s words, we estimate the new Model Y will have a 475-mile range.

These include the newest and larger 4680 batteries with a tabless design. 4680 batteries, so named because of their dimension, 46cm by 80cm, are significantly more energy-dense and cheaper to produce.

Their cost advantage is not only limited to the cheaper raw material they use but they also require a smaller footprint factory and fewer steps to assemble into a cell.

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On top of this, the vehicle is also expected to have a structural battery pack. According to Tesla’s Battery Day demonstration, structural battery packs, unlike regular battery packs which are carried by the body of the car, can be incorporated as weight-bearing components in the chassis.

This allows Tesla to decrease the car’s mass at the same time it improves the vehicle’s stiffness and handling. An important first step to enable a structural battery pack is the ability to build the front and the rear of the vehicle from a single cast part.

Single piece casting is necessary because the batteries are weight-bearing and unless the weight of the vehicle is linearly dispersed, few batteries could be under immense pressure possibly causing damage to the cells.

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Tesla to build the front and rear chassis from a single part utilizes a Giga Press. This is a gigantic machine that takes liquid aluminum and outputs the entire front or rear chassis as a single part.

Currently, Tesla utilizes several Giga Presses at the company’s Fremont California and Shanghai plants. The use of this equipment has allowed Tesla to decrease parts in the rear of the vehicle from 70 to 1.

However, Tesla only uses the gigantic single cast part in the rear of the current Model Y. This means Tesla still needs front casting to enable a structural battery pack.

And now Elon Musk asked if all Tesla models will eventually have their own casting machine to press full chassis, Musk answered saying “all models do make use of aluminum casting, but new Y will be most advanced with 2/3 of body cast.”

This confirms Tesla will at least be using front and rear casting for the new Model Y. At the company’s recent earnings call, Musk had hinted Tesla might be forced to roll back some of the company’s most ambitious plans for the new Model Y.

Related news: Breaking: Tesla To Begin Fully Drivable Refreshed Model Y Test Vehicle Production At Giga Texas

Speaking at the earnings call Musk said Tesla might not necessarily use the 4680 cells in the new Model Y. At the time Elon stated that Tesla has already devised an alternative plan to produce the new Model Y with the current 2170 cells.

It’s nice to hear at least the plan to use front and rear casting in the Model Y will not change.

We will keep you updated if Tesla releases more information regarding the issue. Make sure to visit our site regularly to get the latest update.

So what do you think? What kind of improvements are you expecting from

For more information check out: Tesla Announces 2021 Annual Shareholder Meeting Also, see Elon Musk Announces Giga Berlin County Fair and Tour

Tinsae Aregay has been following Tesla and The evolution of the EV space on a daily basis for several years. He covers everything about Tesla from the cars to Elon Musk, the energy business, and autonomy. Follow Tinsae on Twitter at @TinsaeAregay for daily Tesla news.


DeanMcManis (not verified)    August 15, 2021 - 2:11AM

Hopefully Tesla will get their 4680 battery production scaled up to support the new Model Y. The cast frame and structural pack will improve the Model Y across the board from reduced production costs to a more solid EV. I don't think that the new Model Y's EV range will be anywhere near 475 miles. I think that it may top out around 400 miles. Nobody is even close to that capability now, and it would make more sense for Tesla to hit 400 miles, and have a smaller battery pack. Saving cost and weight.

gery s katona (not verified)    August 16, 2021 - 11:22AM

Sounds like they could be trying to do too much at once which is risky. The 4680's alone are going to be difficult.

Mark (not verified)    August 16, 2021 - 2:39PM

The fact that they have a plan B for 2170 cells is a sign of good management. Adaptability and flexibility is the killer app for the modern business.

ctuna (not verified)    November 2, 2021 - 1:12PM

I don't think there will be any visibility till next year on the 4680 and when an which cars will get it first is still a toss up. But they already said it will be Texas and Berlin plants that get it first. And not in volume till the end of next year at most. The nightmare is they are producing several battery types at the same time an you are not able to specify which you get. Maybe they will have the electric car rebate figured out by Christmas.