It Happened! Elon Musk LEAKED Tesla’s Dry Cathode 4680 Battery to Make EVs Cheaper & Better!

 Imagine a battery that slashes production costs by half and reduces the number of cells needed from 4,400 to just 960 by eliminating traditional tabs and optimizing electron flow. This isn't just an upgrade; it's a game changer that could redefine the future of electric vehicles (EVs). What makes Tesla’s 4680 dry cathode battery a breakthrough in EV technology?

Tesla is currently using 4680 cells to produce structural battery packs for the Model Y. However, these vehicles have encountered issues with poor charging performance and low energy density, leading to their swift removal from the sales catalog. The large size of the 4680 cells makes cooling difficult, limiting the battery’s performance. These problems have become apparent, and Tesla recognizes the need for immediate improvements. A key factor in this improvement is the dry battery electrode (DBE) process.

The dry process eliminates hazardous solvents and oven firing processes, saving time, space, and being more environmentally friendly. Specifically, the dry process is used to produce the anodes of the battery, the conductive electrodes at the edges of the cell, rather than the wet process previously used. Tesla's 4680 cell suppliers, including LG and Panasonic, are working to reduce costs and increase the production of 4680 cells. If Tesla can effectively scale the dry anode method, the production of 4680 cells in battery packs will become cheaper and more efficient.

What makes Tesla’s dry cathode 4680 battery different?

The tabless design of the 4680 also impacts the manufacturing process and ease of production. In conventional lithium-ion cells, metal tabs connect the electrodes outside of the battery and enable current flow. However, these tabs can cause serious issues like increased temperature at the connection points, leading to reduced battery lifespan or even failures. Studies show that hotspots can raise the battery temperature by up to 20°C during a fast charge-discharge cycle. Additionally, attaching tabs to electrodes is a complex process that slows down production speed and increases costs.

Tesla’s choice of a tabless design addresses these issues by completely eliminating traditional metal tabs. Instead, the electrodes are connected directly to the battery’s end through multiple small contact points along the edge of the electrodes. As a result, the battery operates at a more stable temperature, extending the battery’s life, with the average operating temperature reduced by about 10% compared to regular tab designs. At the same time, the battery manufacturing process becomes simpler, which speeds up production and reduces costs. Tesla forecasts that the tabless design could cut the production cost per kilowatt-hour of the 4680 battery to under $70, compared to the $100-$150 per kilowatt-hour of traditional batteries.

Removing Tabs: Why Did Tesla Decide to Remove Tabs from the Batteries?

Removing tabs in the battery design not only improves durability and overall performance but also plays a crucial role in optimizing the distance electrons need to travel inside the battery. This directly impacts the battery’s charge-discharge performance and its ability to deliver more energy efficiently. Eliminating tabs also shortens the distance electrons need to travel in and out of the battery, meaning less resistance and less energy lost during this process, which enhances the overall efficiency of Tesla vehicles.

Experts suggest that in a tab design, the distance electrons must travel from distant regions of the electrode to the tab can be several centimeters, depending on the battery size. For example, in a cylindrical cell with a diameter of 18 mm, the travel distance can be up to 9 mm from the center of the electrode to the tab. This distance creates resistance differences on the electrode surface, leading to energy loss as heat, causing overheating, and affecting the battery’s lifespan. By removing the tabs in the 4680 battery design, Tesla has reduced the distance the electrons need to travel. Instead of going to the central point, electrons can pass through multiple connection points along the edge of the electrode, shortening the travel distance to just a few millimeters or even less, depending on the location of the contact points.

How Do the Structural Advantages of the 4680 Cell Contribute to Reducing Vehicle Production Costs?

Tesla’s new 4680 cell manufacturing process offers several advantages over the traditional wet process, particularly regarding cost. It’s estimated that the dry process can reduce total costs by up to half. This savings primarily comes from cutting expensive solvents and the energy-intensive drying process used in the wet method. Specifically, the solvent NMP used in the wet battery electrode process requires recycling or disposal, significantly increasing production costs. The dry process removes these steps, substantially reducing material and energy costs.

In addition to cost benefits, the dry process also increases production speed and is related to environmental protection. The dry process not only helps lower costs but also accelerates production by eliminating steps like drying and solvent recycling. The 4680 cell manufacturing process is a lot faster, allowing Tesla to up their output without expanding their factory scale. Moreover, the dry process is more environmentally friendly, cutting the emission of hazardous chemicals and saving energy, thereby contributing to a lower environmental impact when making batteries.

Tesla’s Strategy to Optimize 4680 Battery Production in the Final Months of the Year

According to a report by Chinese Late Post citing internal sources, Elon Musk aims to produce the first mass-produced 4680 cells with dry-coated electrodes before the end of the year and use them in customer vehicles. If this proves effective, Tesla may abandon the 4680 cells made using the wet process. Late Post reports that the 4680 cells currently installed in the Cybertruck are hybrid types, with the anode being dry-coated, but the cathode has not been. Tesla still sources the cathodes from suppliers like LG, where they’re coated using the traditional wet process.

Why Tesla Prioritizes Internal Battery Upgrades Over Purchasing from Established Battery Manufacturers

Tesla’s decision to develop and manufacture its own batteries, particularly the 4680 battery, reflects a long-term strategy that gives several competitive advantages, helping the company maintain its leading position in the global EV market. While many of Tesla’s competitors, like GM and Volkswagen, rely on external suppliers for their EV batteries, Tesla’s approach enables them to optimize production costs and maximize profits.

Tesla’s competitors need to purchase batteries from external suppliers, making it challenging for them to optimize production costs and maximize profits. Battery prices, which account for about 30 to 40% of the total cost of EVs, are a significant factor in overall vehicle pricing. By developing its own battery technology, Tesla can better control these costs, leading to greater profitability and the ability to pass savings on to consumers. This strategy positions Tesla to continue leading in the increasingly competitive EV market.