Key Battery Production Figures and Expansion Plans
The 4680 batteries used in the Cybertruck require Tesla to manufacture an estimated 340 million cells per year, or almost a million cells daily, to meet the demand of producing 250,000 electric pickups annually. However, Tesla’s Austin factory currently takes about 16 weeks to produce 10 million 4680 cells, serving only around 24,000 pickups per year.
In addition to supplying the Cybertruck, Tesla plans to use the 4680 batteries in other vehicles such as a $25,000 small car scheduled for launch in the mid-2020s. While Tesla has limited production capacity for 4680 cells in its Fremont, California plant, it primarily focuses on pilot production. Battery supplier Panasonic is also in the early stages of building two battery plants in the United States.
Ramping Up Production and Overcoming Challenges
Tesla aims to increase 4680 battery production by scaling up its battery lines in the Austin factory. As of now, two production lines are functioning, with plans to install a total of eight lines in two phases, expected to be completed by late 2024. However, replicating production know-how from one line to the next poses its own set of difficulties.
The process of dry-coating cathodes, specifically mixing cathode materials without moisture and binding them to metallic foil, has proven challenging when scaled up. Tesla has encountered issues with heat generation during the process, which causes the binder to melt. Tesla is also grappling with the even application of pressure during electrode coating, resulting in uneven surfaces and thickness that render cells unusable.
Furthermore, Tesla is in the process of creating a new quality verification system to identify flaws in coating, as some may not be immediately visible. The company’s data infrastructure is being built to ensure effective monitoring of battery development, manufacturing, and performance in the field.