Tesla works with a semi-solid state battery expert to produce 4680 cells in large quantities at a lower cost

Photo Credit: History-Computer Tesla currently uses 4680 battery packs in its Model Y, which is barely halfway toward the company's stated objective of a 50% cost savings over traditional batteries. Tesla has now employed a solid-state battery specialist who is solely focused on the problem because it has yet to perfect mass dry electrode production in order to realize the full potential of the 4680 cells. Tesla revealed a larger 4680 cell for use in electric vehicle power packs that would cost half as much as its current 2170 batteries on Battery Day 2020. However, it appears that the structural 4680 battery pack costs only US$3,600 less than the 2170 cell counterpart, which Tesla began installing in the Model Y built at Giga Texas. As a result of the 4680-type battery's sole physical benefits rather than some ground-breaking chemistry discovery, the savings are fairly meager in comparison to the enormous 4680 promises. Photo Credit: Teslarati The 4680 cells, which are significantly larger than the 2170 cells, are installed as a direct cell-to-pack arrangement as an integral part of the vehicle's body and can act as structural support. This significantly increases volume utilization and results in a battery that is much lighter because there are far fewer welding sites needed for the 830 (rather than 4,400) cells. The 4680 structural pack of the Model Y is now sealed as part of the chassis, which makes it extremely difficult to repair individual cells. Also Read: Tesla Model 3 Prices Drop, but Model S and X Prices Stay the Same If Tesla wants to hit the targeted US$5,000 or so price point per Model Y pack, it must now master the trickier aspect of the 4680 battery cost savings, making the electrodes using a dry coating process. Industry experts predict that this would enable Tesla to reduce the price of the Model Y by an additional US$5,280. It takes a lot of time, effort, and dangerous chemicals to apply the current standard wet coating to the 4680 cathode, which is a nasty procedure. On the other hand, the dry coating approach may be used in a much smaller facility and is safer, less expensive, and more convenient. As a result of Tesla's acquisition of dry process startup Maxwell Technologies in 2019, the 4680 Battery Day presentation on the 4680 cell's potential was extravagant. Tesla is now engaging experts from outside the company to assist with the process because it was unable to successfully replicate the technology on a large scale for mass production. Photo Credit: Teslarati According to rumors, Tesla has hired Matt Tyler, 24M's VP of advanced manufacturing, who has spent the previous six years working on the creation of a semi-solid battery. The development of "an ultra-thick SemiSolid cathode made up of sophisticated cobalt- and nickel-free sodium cathode active material" is one of 24M's innovations. That is almost equivalent to the dry cathode coating method that the largest EV manufacturer in the world is looking to mass produce. Tesla left little room for interpretation as to why it selected Mr. Tyler for the job of "Director of Dry Electrode Development" at its cutting-edge 4680 facility in the Fremont factory. Also Read: In a stunning render image, the Volkswagen ID.2 X, a small electric SUV competes with the Tesla Model 2 from VW Tesla had hoped to make a breakthrough in dry electrode production by the end of 2022, but that didn't happen, so the company is now keen to lead the way this year. As it has created an EV pricing war, scaling production of as inexpensive 4680 cells will be essential for maintaining its excellent profit margins. The Nevada Gigafactory's massive 100 GWh 4680 battery capacity increase, which Tesla recently announced, may bring in US$3.5 billion in federal tax credits yearly. Tesla has a good chance of surpassing other EV manufacturers in terms of cost-effectiveness if it can figure out the mass dry cathode production challenge by that time and with government subsidies in place.