Tesla, the pioneering electric vehicle manufacturer, has been diligently working on its innovative 4680 battery cells, distinct for their taller and wider dimensions compared to conventional counterparts. The key differentiator lies not only in the format but in the groundbreaking dry electrode process adopted by Tesla, a significant departure from the wet paste technique prevalent in the industry.
Acquiring Maxwell Technologies five years ago for its dry electrode expertise, Tesla aims to reduce production costs by minimizing energy requirements and factory space dedicated to the drying process. However, recent reports suggest that Tesla is encountering hurdles in scaling up the dry coating process at its Gigafactory in Austin, Texas.
Insiders familiar with the matter claim that Tesla has yet to fully master the dry coating process, especially for the cathode, a critical and expensive component of the battery. While dry coating has proven successful in laboratory settings and for smaller energy storage devices, the challenge lies in commercializing it for large-scale electric vehicle (EV) batteries at a high production speed.
Sources indicate that Tesla’s current production rate falls short of its ambitious target to produce 250,000 electric pickups, including the Cybertruck, by 2025. The Gigafactory in Austin, which manufactures 4680 cells using dry-coated electrodes, is reportedly struggling to achieve the necessary scale. Dry coating the anode appears manageable, but perfecting the technique for the cathode remains a formidable challenge.
Battery technology consultant Yuan Gao emphasizes the novelty of Tesla’s endeavor, stating that while dry coating is proven in the laboratory, no one has attempted it at the mass scale and speed required for large EV batteries. Gao notes that scaling up the process, developing specialized equipment, and ensuring stability present daunting tasks for Tesla.
According to sources, the 4680 battery packs in Cybertrucks consist of approximately 1,360 individual cells. To meet the production goal of 250,000 electric pickups, Tesla would need to manufacture nearly a million cells daily. Presently, the Gigafactory requires approximately 16 weeks to produce 10 million 4680 cells.
While Tesla has expressed its intention to use the 4680 battery cells for both the Cybertruck and the rumored Model 2, current production levels fall short of demand. Limited production capacity for 4680 cells in Fremont, California, and Panasonic’s ongoing construction of battery plants further underscore the challenges in meeting production targets.
Despite the current obstacles, some sources remain optimistic, suggesting that Tesla’s production of 4680 cells could gain momentum once stability is achieved on one production line. Drew Baglino, the head of Tesla’s battery operations, has mentioned the company’s ongoing production of 4680 cells on two lines in Austin, with plans to install a total of eight lines by late 2024.
The transition from one production line to another poses difficulties, with potential increases in scrappage rates during the initial stages of each new line. Challenges include maintaining even pressure on large rollers used to coat metallic foil for battery electrodes, leading to uneven surfaces and thickness.
Notably, Tesla faces complexities in identifying flaws in the coating, necessitating the development of a robust quality verification system. Despite these challenges, the company’s commitment to innovation and perseverance in overcoming obstacles echoes a spirit reminiscent of historical feats, embodying the adage, “The difficult we do right away. The impossible takes a little longer.” Tesla, led by Elon Musk and his team, remains dedicated to pushing the boundaries of electric vehicle technology, even if perfection takes time.
