Featured image: Tesla

The structure of a car is a critical component of its efficiency and performance. This is why Tesla is deeply focused on continuing to enhance its vehicles' structure. During Battery Day, the company announced that it will improve the design of its vehicles using a new battery architecture--utilizing a truly radical approach to manufacturing car parts.

For some time now, Tesla has been developing a plan--incorporating a huge machine--to reduce the number of parts for making car frames. As a result, the company introduced the Giga Press, which is capable of casting the rear aspect of the Model Y frame in one piece.

And it recently became known that, in addition to the rear end, Tesla will also produce the Model Y front end frame in one single piece. This will not only improve production efficiency and performance, but also improve driver/passenger safety.

Beyond enhancing safety, manufacturing in this way significantly reduces assembly time, operating costs, production costs, plant area, plant production costs, tools, and equipment costs.

The one-piece parts are made from Tesla's proprietary aluminum alloy, which is highly durable due to no heat treatments or coatings that could otherwise compromise the structural integrity of the part.

Source: Tesla

In addition to bolstering the car's frame, Tesla plans to drastically improve the design of its vehicles using a new battery architecture. With the new form factor, Tesla is able to minimize negative mass, thus increasing the density of the battery pack. The battery is then able to be positioned more efficiently, further reducing redundant structures within the packaging itself.

The car's chassis, with two one-piece molded parts for the front and rear, allows the battery to be placed in the middle. As a result, this greatly simplifies production. Also, because the battery can be located in the center of the car, its safety is increased. Now its cars can be even more protected from side impact.

In addition, a centrally located battery enhances driving performance, namely agility. These improvements also result in a 10% weight reduction, a 14% increase in range, a significant reduction in the number of parts, and the overall increased structural integrity of the vehicle.

Tesla's plan to utilize structural batteries is likely underestimated. Given the impressive improvements presented at Battery Day, this major structural innovation demonstrates yet again how Tesla is revolutionizing the industry. This particular design advancement will significantly reduce production costs, yet all-the-while increase vehicle safety, reliability, range, and driving performance. Whether the significance of Battery Day is fully appreciated now, ultimately, within 18-36 months, the entire industry will feel the significant impact of these game-changing innovations.

© 2020, Eva Fox. All rights reserved.

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Article edited by @SmokeyShorts, you can follow him on Twitter

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