All told, Tesla’s new 4680 battery cell represents a paradigm shift in automotive energy storage. The new cells are far cheaper and can store far more power per unit of volume. They have been redesigned a as structural elements of the vehicle, resulting in a cheaper, more rigid vehicle.
Tesla rolled out hundreds if not thousands of small improvements today that bring step change improvements to the fundamental building block of Tesla’s business — the battery cell.
- 14% improvement in cost/kWh coming from the change in cell form factor.
- 18% improvement in cost/kWh as a result of the 10× manufacturing footprint reduction and 10× manufacturing energy consumption reduction. The new dry manufacturing process enables pressing the active battery powder material directly into a film. The new manufacturing process is based on Maxwell Technologies’ proprietary “proof of concept” process. Process is not at production scale yet, but there is a “clear path” to large scale production.
- 5% improvement in cost/kWh coming from the increase utilization of silicon in the battery cells.
- 12% reduction in cost/kWh coming from improvements in the cathode material.
- 7% improvement in battery pack cost per kWh as a result of Tesla’s new integrated vehicle design. Tesla redesigned its vehicles using new front and rear castings that integrate with the battery pack. To accomplish this, Tesla developed a completely new alloy to enable casting of some of the largest components in the automotive space. These bolt directly into a new “structural battery,” eliminating the need for redundant, parallel elements in Teslas.
All told, Tesla’s redesign of the battery, cathode, and vehicle frame translate to an expected improvement of 56% in Tesla’s cost per kWh. That’s a game changer for Tesla and will enable a completely new generation of low cost electric vehicles. It all starts with the humble battery cell. Tesla has made significant progress in rethinking the battery cell and is well along the way to rolling these new cells into production. But all told, it will take the company 18 months for most of these changes to get to production.
Tesla didn't hold back at Battery Day, announcing a new tabless 4680 cell form factor, among many other things.
cleantechnica.com