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Tesla to focus on existing gigacast tech for unboxed process: report

Credit: Idea Group/YouTube

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A recent report from Reuters has claimed that Tesla is stepping back from its plan of developing a next-generation gigacasting system that would have allowed the company to use a single casting for a vehicle’s entire underbody. Instead, the publication claimed that Tesla would be sticking with its tried and tested process of using a front and rear megacast and a structural battery pack. 

Last September, Reuters claimed that Tesla was developing a system that would allow the company to cast the entire underbody of a car in one piece. The publication claimed that the single-piece gigacast would be a central component of the company’s “unboxed” process. Citing people reportedly familiar with the matter in its recent report, Reuters claimed that Tesla stepped back from its single-piece gigacast plans last Autumn. 

It should be noted that when Tesla discussed its “unboxed process” during Investor Day 2023, the company’s graphics depicted a two-megacast solution, not a single-piece gigacast. The Robotaxi “Cybercab” is a vehicle that will be built on a new platform, so it makes sense for Tesla to focus on tried and tested technologies for the vehicle’s production. 

Developing a single-piece gigacast would require a lot of trial and error, as well as a notable amount of investment on Tesla’s part. The company may be a pioneer in the use of gigacastings, but the company had to invest a notable amount of resources on its existing 6,000 to 9,000-ton Giga Press machines. Pursuing a single-piece gigacast for the Robotaxi would have required Tesla to develop a manufacturing system centered on a Giga Press that’s far larger than anything it has in its arsenal today — an endeavor that’s likely very costly. 

While Reuters‘ report adopted an angle which suggested that Tesla was walking away from its single-piece gigacast plans as a response to weak sales and rising competition, the company’s alleged decision to use its existing gigacasting tech for the Robotaxi “Cybercab” has been teased by Elon Musk during Tesla’s Q1 earnings call. In his opening remarks, Musk noted that Tesla is accelerating the launch of new models by combining aspects of its current platform and its next-generation platform. 

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“We’ve updated our future vehicle lineup to accelerate the launch of new models ahead, previously mentioned start of production in the second half of 2025. So, we expect it to be more like the early 2025, if not late this year. These new vehicles, including more affordable models, will use aspects of the next-generation platform as well as aspects of our current platforms, and we’ll be able to produce on the same manufacturing lines as our current vehicle lineup. So, it’s not contingent upon any new factory or massive new production line. It will be made on our current production lines much more efficiently,” Musk said.  

Watch Tesla executives discuss the unboxed process in the video below.

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Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Stellantis unveils solid-state battery for EVs

Stellantis validated solid state battery cells for EVs: ultra-dense, fast-charging, and AI-optimized. Launching demo fleet by 2026.

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(Credit: Stellantis)

Stellantis N.V. and Factorial Energy have validated Factorial’s automotive-sized FEST® solid-state battery cells, a major milestone for next-generation electric vehicle (EV) batteries. The breakthrough positions Stellantis and Factorial to advance EV performance with lighter, more efficient batteries.

“Reaching this level of performance reflects the strengths of our collaboration with Factorial.

“This breakthrough puts us at the forefront of the solid-state revolution, but we are not stopping there. We continue working together to push the boundaries and deliver even more advanced solutions, bringing us closer to lighter, more efficient batteries that reduce costs for our customers,” said Ned Curic, Stellanti’s Chief Engineering and Technology Officer.

The 77Ah FEST® cells achieved an energy density of 375Wh/kg, supporting over 600 cycles toward automotive qualification. Unlike lithium-ion batteries, these solid-state cells charge from 15% to over 90% in 18 minutes at room temperature and deliver high power with discharge rates up to 4C. Factorial’s AI-driven electrolyte formulation enables performance in temperatures from -30°C to 45°C (-22°F to 113°F), overcoming previous solid-state limitations.

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“Battery development is about compromise. While optimizing one feature is simple, balancing high energy density, cycle life, fast charging, and safety in an automotive-sized battery with OEM validation is a breakthrough,” said Siyu Huang, CEO of Factorial Energy. “This achievement with Stellantis is bringing next-generation battery technology from research to reality.”

The collaboration optimizes battery pack design for reduced weight and improved efficiency, enhancing vehicle range and affordability. Stellantis invested $75 million in Factorial in 2021 and plans to integrate these batteries into a demonstration fleet by 2026. This fleet will validate the technology’s real-world performance, a critical step toward commercialization.

The milestone aligns with Stellantis’ push for sustainable EV solutions, leveraging Factorial’s disruptive technology to meet the rising demand for high-performance batteries. As the companies refine pack architecture, the validated cells promise faster charging and greater efficiency, potentially reshaping the EV market. With the demonstration fleet on the horizon, Stellantis and Factorial are poised to lead the solid-state battery push, delivering cost-effective, high-range EVs to consumers.

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Tesla China vehicle registrations rise 51% in April’s fourth week

In the week ending April 27, Tesla China saw 10,300 new vehicle registrations.

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Credit: Tesla China

Tesla China’s new vehicle registrations saw a notable rise in the week of April 21-27, 2025. Over the week, the electric vehicle maker’s registrations saw an impressive 51% week-over-week rise, suggesting that domestic vehicle deliveries are on the rise once more. 

Tesla China Results

In the week ending April 27, Tesla China saw 10,300 new vehicle registrations. This represents a notable rise from the company’s registration numbers in the past weeks of April. For context, Tesla China saw 3,600 registrations in the week ending April 6, 5,400 registrations in the week ending April 13, and 6,780 registrations in the week ending April 20, 2025.

Considering that April is the first month of the second quarter, expectations were high that Tesla China was allocating Giga Shanghai’s output for vehicle exports. With 10,300 registrations in the week ending April 27, however, it would appear that the company’s domestic deliveries are picking up once more.

Tesla China does not report its weekly sales figures, though a general idea of the company’s overall perforce in the domestic auto sector can be inferred through new vehicle registrations. Fortunately, these registrations are closely tracked by industry watchers, as well as some local automakers like Li Auto.

Tesla Model 3 and Model Y in Focus

Tesla China produces the Model Y and Model 3 in Giga Shanghai. Both vehicles are also exported from China to foreign territories. As per industry watchers, it would appear that both the Model 3 and Model Y saw an increase in registrations in the week ending April 27.

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The Model 3, for one, appears to have seen 3,200 registrations in the week ending April 27, a 14% increase from the 2,800 that were registered in the week ending April 20. For context, Tesla China saw just 1,500 new Model 3 registrations in the week ending April 13 and 1,040 registrations in the week ending April 6.

The Model Y, on the other hand, saw 7,100 registrations in the week ending April 27. That’s a 77.5% increase from the 4,000 that were registered in the week ending April 20. Tesla also saw 3,900 registrations in the week ending April 13, and 2,540 registrations in the week ending April 6, 2025.

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Volkswagen teams with Uber for robotaxi service with the ID. Buzz

Volkswagen and Uber team up to launch a driverless ID. Buzz robotaxi fleet in U.S. cities. Testing starts in LA this year.

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(Credit: Volkswagen)

Volkswagen of America and Uber unveiled a plan to launch a commercial robotaxi service using autonomous electric ID. Buzz vehicles across U.S. cities over the next decade. The partnership marks a significant step for Volkswagen’s autonomous vehicle ambitions, leveraging Uber’s ride-hailing expertise.

The service will debut in Los Angeles by late 2026, with human safety operators initially overseeing the fleet before transitioning to fully driverless operations in 2027. Volkswagen ADMT, the German automaker’s autonomous subsidiary, will begin testing in Los Angeles later this year upon securing a testing permit from the California Department of Motor Vehicles. The California Public Utilities Commission will oversee permits for the commercial ride-hailing phase.

“Volkswagen is not just a car manufacturer — we are shaping the future of mobility, and our collaboration with Uber accelerates that vision,” said Christian Senger, CEO of Volkswagen Autonomous Mobility. “What really sets us apart is our ability to combine the best of both worlds–high-volume manufacturing expertise with cutting-edge technology and a deep understanding of urban mobility needs.”

The Trump administration’s recent policy shift, announced last Thursday by Transportation Secretary Sean Duffy, supports initiatives like VW and Uber’s partnerships by easing federal safety rules and crash reporting requirements on autonomous vehicle development. According to Duffy, the United States government wants to outpace Chinese competitors in autonomous vehicle development.

Volkswagen ADMT, which launched publicly in July 2023, has been testing 10 ID. Buzz vehicles equipped with Mobileye’s autonomous technology in Austin, reported TechCrunch. Two years ago, Volkswagen focused on selling self-driving vans and fleet management software rather than building its own ride-hailing service. VW’s strategy toward autonomous vehicles appears to have shifted, as reflected in its Uber partnership.

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Uber will strengthen its autonomous vehicle portfolio through its partnership with Volkswagen. The ride-hailing service company has secured deals with over 14 firms, including Waymo in Austin and a forthcoming launch in Atlanta.

The Volkswagen-Uber collaboration positions both companies to capitalize on the growing robotaxi market. With testing imminent and regulatory support increasing, the ID. Buzz fleet could redefine urban mobility, blending Volkswagen’s manufacturing prowess with Uber’s ride-hailing network to compete in the evolving autonomous vehicle landscape.

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