Tesla is no stranger to shattering the status quo. Sources close to the matter reveal that the electric carmaker is on the cusp of another monumental leap. This time, Tesla aims to revolutionize the way electric vehicles (EVs) are manufactured, thereby paving the way for the much-anticipated ‘Tesla Model 2’.

Gigacasting: The Technology That Left Rivals Scrambling

Tesla already turned heads with its “gigacasting” technology, which utilizes enormous presses with clamping pressures between 6,000 and 9,000 tons. This technique allows for the molding of front and rear structures of its Model Y in a single process, substantially cutting down on production costs.

But the company isn’t stopping there.

One-Piece Underbody: The Future of EV Manufacturing

In an unprecedented move, Tesla is reportedly close to perfecting a method that will enable them to die-cast the complex underbody of an electric vehicle in one piece. Traditional vehicles require about 400 separate parts to accomplish this. Terry Woychowski, president of U.S. engineering company Caresoft Global, commented, “It’s an enabler on steroids. It has a huge implication for the industry, but it’s a very challenging task.”

The Innovations Behind the Breakthrough

The marvel isn’t just in the end product but also in the technologies used to get there. The company has harnessed the power of 3D printing and industrial sand to create test molds for these large parts. These innovations have allowed Tesla to cut down the design validation cycle to just 2-3 months, a fraction of what it would take with traditional methods.

Tailor-Made Alloys and the Underlying Challenges

Creating a one-piece underbody comes with its own set of challenges, especially when it comes to material properties. Traditional aluminum alloys failed to meet Tesla’s strict criteria for crashworthiness and other attributes. However, casting specialists have formulated special alloys and fine-tuned the cooling process of the molten alloy, thereby overcoming these hurdles.

Implications for the Tesla Model 2

All these innovations are not just a showcase of engineering prowess; they have direct implications for the upcoming affordable Tesla, christened, much against Elon Musk’s wishes, the Tesla Model 2 by the Tesla community. Insiders confirm that these manufacturing advancements could find their first real-world application in Tesla’s small EV, aimed to launch with a price tag of just $25,000. Tesla Model 2 is rumored to have features like a new generation of electric motors that don’t use any rare earth metals, a more efficient battery technology, and much more. The vehicle will reportedly resemble the Cybertruck, according to Elon Musk’s biography.

What Lies Ahead?

Tesla’s groundbreaking manufacturing techniques are more than just a technological spectacle; they mark a paradigm shift in how cars—electric or otherwise—are designed and produced. With Tesla Model 2 as the likely first recipient of these innovations, the electric vehicle landscape is poised for a transformation that could very well redefine the concept of mass-market cars.

As the industry watches with bated breath, Tesla continues to push the boundaries of what’s possible, leaving us to ponder: What else is up Tesla’s sleeve?