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EXCLUSIVE: Tesla Cybertruck battery packs to be built at Fremont Factory

October 19, 2022

Reported by Teslarati: https://www.teslarati.com/tesla-cybertruck-battery-packs-fremont-production/

Tesla plans to start building battery packs for the upcoming Cybertruck on a new cell manufacturing line in the Fremont factory, people with knowledge of the project told Teslarati.

In August, we reported that Tesla had filed to build a new battery manufacturing equipment line on the second floor of the Fremont factory. This filing, which was submitted to the City of Fremont on August 30, relates to the module portion of the line, Tesla said.

Tesla described the project as “CTA Battery B-Build,” the filing shows.


Tesla Cybertruck Report: Cybertruck Battery Pack Production Will Initially Begin at Tesla Fremont Factory tesla-battery-cell-manufacturing-filing-fremont



Tesla is ultimately planning to build the Cybertruck in Austin at Gigafactory Texas. However, battery cells and cell pack manufacturing are not yet ready to take off at the new Tesla plant, which is located just outside Austin. Tesla applied to build a battery and cathode manufacturing building at Gigafactory Texas earlier this year, and while the project has been started, it likely will not be ready for the Cybertruck’s projected launch in mid-2023.

With an extensive order log that features over 1 million total reservations, Tesla is preparing for Cybertruck manufacturing by building the battery packs at a plant that is already operational. The Fremont facility, the only Tesla plant manufacturing all four vehicles the company builds, was ultimately chosen for the task of kicking off Cybertruck pack manufacturing, Teslarati confirmed with sources familiar with the matter.

CYBERTRUCK BATTERY PACK MANUFACTURING WILL START IN FREMONT
Sources familiar with the matter told Teslarati the second-floor manufacturing line that Tesla filed to build in August will manufacture the Cybertruck packs. Tesla will take the 4680 battery cells produced at the Kato Road facility or another previously utilized cell design manufactured at Gigafactory Nevada and put them into modules and packs that are manufactured on the new Fremont battery line.

Currently, the line is being completed by construction crews on site, who are making daily progress. Additionally, Tesla engineers are installing automation equipment to produce the Cybertruck battery packs.

Tesla did not immediately respond to our request for comment.

KICKING CYBERTRUCK MODULE PRODUCTION INTO “PLAID MODE”
Tesla is also working hard to kick off Cybertruck pack production as time is extremely limited. Tesla has a series of vehicles, referred to as “carriers,” which transport batteries throughout the factory. The company recently ordered around 300 new carriers for the factory as cell and battery pack manufacturing is set to ramp drastically.

The sources also said the Cybertruck battery pack line is currently being tested with Tesla’s automation equipment. Tesla is working to ramp the line quickly as Cybertruck vehicle manufacturing is planned for next year at Gigafactory Texas.

2023: THE YEAR OF THE TESLA CYBERTRUCK?
Tesla is set to build the Cybertruck at Gigafactory Texas. After unveiling the all-electric pickup in 2019, Tesla has delayed initial production on several occasions due to supply chain issues and other challenges.

“In 2022, supply chain will continue to be the fundamental limiter of output across all factories,” Musk said during Tesla’s Q4 and 2021 Full Year Earnings Call in January. So the chip shortage, while better than last year, is still an issue. And, yeah, so that’s — there are multiple supply chain challenges.”

Musk went on to say that the challenges would delay the launch of any new products in 2022. “We will, however, do a lot of engineering and tooling, what not to create those vehicles: Cybertruck, Semi, Roadster, Optimus, and be ready to bring those to production hopefully next year. That is most likely.”

Although Tesla is planning to begin deliveries of the Semi on December 1, all other projects have been effectively delayed until next year, but preparation to launch those projects is evidently a priority within the factories.

4680 CELLS ARE NOT CONSTRAINED BUT ARE THEY GOING INTO THE CYBERTRUCK?
Tesla’s Vice President of Powertrain Drew Baglino detailed earlier this year that the company was not constrained in terms of 4680 battery cell availability.

“So throughout 2021, we focused on growing cell supply alongside our in-house 4680 effort to provide us flexibility and insurance as we attempt to grow as fast as possible,” Baglino said on the Q4 and Full Year 2021 Earnings Call in January. “4680 cells are not a constraint to our 2022 volume plans based on the information we have.”

What Baglino said next on the call likely indicates what Tesla was preparing for with the Cybertruck: pack manufacturing at Fremont, shipping the packs to Texas, and then installing them into vehicles:

“But we are making meaningful progress of the ramp curve in Kato. We’re building 4680 structural packs every day, which are being assembled into vehicles in Texas. I was driving one yesterday and the day before. And we believe our first 4680 vehicles will be delivered this quarter.”

The Kato Road facility has supported Tesla’s 4680 cell needs thus far. The 4680 packs were installed on some Gigafactory Texas-built Model Ys, and were reviewed by Munro Live earlier this year. Fremont will likely support Cybertruck pack manufacturing for some time, utilizing cells from Kato Road and from suppliers like Panasonic when they ultimately being manufacturing the battery for Tesla.

As Cybertruck manufacturing ramps up into late 2023, 2024, and beyond, packs will then be at Fremont and Gigafactory Texas, which would likely entirely support Cybertruck production.
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Tinker71

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OK I will go first.

I think this means the initial ramp will be very slow. Tesla has not solved all their battery chemistry problems and the first models will come out with a different pack than the main release. I think it will have a range of around 420 miles (maybe as low as 350) in a single stack configuration using the current cells.

This may be the CT2 now a quad motor. (software limited as people have speculated) The 500 mile range version will come later with improved cells.

Ugh. I don't know were the Plaid fits in here. I thought TSLA would release it first to skim the cream, but who wants a PLAID without the best battery pack?
 

greggertruck

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Good points @Tinker71
I however wonder if they’re in fact just utilizing both facilities for Cybertruck and semi battery manufacturing.

one day I hear they’re stock piling batteries, the next it’s they are having to use Fremont “instead”.

it’s highly logical they’re using both, but I’d be curious how Sparks is doing too.
 

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Good points @Tinker71
I however wonder if they’re in fact just utilizing both facilities for Cybertruck and semi battery manufacturing.

one day I hear they’re stock piling batteries, the next it’s they are having to use Fremont “instead”.

it’s highly logical they’re using both, but I’d be curious how Sparks is doing too.
I don't think the battery pack is that complicated (all things considering). Wouldn't it be cheaper to ship the cells? IDK if they are transporting battery packs they will be weight limited before space limited on trucks.

Will they transport by rail?

This is why I think this first pack will be different from the Texas packs.
 

greggertruck

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Pack alone is very important. But they have a bunch of weight savings as we’ve all covered. Most interestingly the (rumored, recycled) paper dashboard.
It could have the same pack size as rivian or does but go further simply because teslas chemistry, but the weight will play a huge roll!
 


Macgyverfever

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This is all my opinion but range might be a moot point; all a manufacturer has to do to increase range is add more batteries, but that then hurts efficiency. Luxury moving-forward isn't about short ranges and parlor tricks; it's about the entire package, and if the 4680 batteries haven't crossed a certain threshold of energy density, then they won't be in the plaid.

I also believe the quad variant will offer a crabwalk mode software package to purchase separately unless you get plaid.
 

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There will be 500 mile plus unit. It is just a matter of when. I don't think Tesla made any commitment to produce the CT3 first.

This big question in my mind is single vs double stacking batteries. At one point double stacking was the favored theory but it adds a layer of complexity. (pun)

IDK. Maybe Fremont will make the 500+ pack first and it will be a PLAID. That might make sense for the lowish volume?? If this is the case the chemistry improvements may already have been figured out on the Kato line??
 

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Tinker71

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This is super encouraging to me. Giga casting, battery pack, H4 chipset (check) My last concern is body forming. Everything else has been done to some degree. As a mid pack reservation holder I don't care about what is produced first. They just need to start producing. The ramp will come and there will be some changes by the time I am called.
 


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I don't think the battery pack is that complicated (all things considering). Wouldn't it be cheaper to ship the cells?


Jordan explains in this video that the cells in a pack must be perfectly matched to each other, with respect to voltage. Any mismatched cell will do more work, or become overcharged, eventually leading to premature cell failure.

Since this process of voltage-matching is done during proofing, it makes sense that the packs would then be built with the matched set of cells.
 

Crissa

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Good points @Tinker71
I however wonder if they’re in fact just utilizing both facilities for Cybertruck and semi battery manufacturing.

one day I hear they’re stock piling batteries, the next it’s they are having to use Fremont “instead”.

it’s highly logical they’re using both, but I’d be curious how Sparks is doing too.
The Semi packs are made in Nevada.

This is just a test line. Why ship the batteries from Kato for an experimental line when you can do it down the street? It's what they did for the Model Y. While it's making and perfecting how to make Cybertruck packs, the cells made in Austin can go straight into Model Y.

This only reinforces that the assembly line is being designed in Fremont (and like every company before them has found out, despite housing costs, engineers would rather live in California.)

-Crissa

Tesla Cybertruck Report: Cybertruck Battery Pack Production Will Initially Begin at Tesla Fremont Factory C0A94297-F62D-477C-898B-3C8814503D72
 

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Jordan explains in this video that the cells in a pack must be perfectly matched to each other, with respect to voltage. Any mismatched cell will do more work, or become overcharged, eventually leading to premature cell failure.

Since this process of voltage-matching is done during proofing, it makes sense that the packs would then be built with the matched set of cells.
I agree it is technical, but it has been done before. It may be a higher voltage but it should be fairly similar to the model y structural pack.
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