Tesla Model Y Texas-Built Giga Castings Removed!

[@metriczeppelin]

Being a 60 something year old motorhead, watching this vid and listening to the engineering terms and acronym's continues to fascinate me. The front and rear castings are actual engineering works of art. Does that make sense? Truly 21st century stuff. Thanks so much! Cheers

[@Capthrax1]

you should look at a video of the casting machine in action. its amazing.

[@fonkenful]

@@Capthrax1 Indeed, INDRA deserves at least as much credit for implementation of the machinery to achieve the results as do the imagineers at Tesla. While the best part might well be no part, it’s far more complicated to get to that level of simplicity than many of us self appointed You Tube experts can fully comprehend.

[@pierrembadenhorstt]

what a time to be alive

[@nomayor1]

Yes they are. Until you realise that after a crash when the casting, like any casting, crumbles into a million pieces, your car is unrepairable.

[@peterlittlejohn8933]

@@nomayor1 Then you realise you are still in a repairable condition after the crash. All because the casting crumbled into a million pieces.....not you.

[@ryanchappell5962]

This was one of the coolest sponsor spots I’ve seen. You didn’t spend a lot of time on it and you completely disassembled and expertly analyzed the product. Very nice.

[@markkoons7488]

As an old guy who worked on GM and Chrysler assembly lines more than 50 years ago and who both helped install early robotics and later toured highly roboticised factories, this report is fascinating. Thank you.

[@johnleeinslc]

As a Tesla owner and volunteer fireman, I am quite interested in how the casting affects the 'jaws of life' extraction operations. If you can contact your local fire department and have them inspect the front casting, and ideally have them try cutting and spreading the casting behind the door hinge - SOP for a dash displacement extraction - it would help safety of all Tesla owners who may need a first responder on one of their worst days of their life.

[@mbox314]

I am sure the casting can yield but instead of bending it will Crack and send sharp aluminum chunks flying. I am guessing of course based on my limited experence smashing up aluminum casting with a sledge hammer.

[@NTNLabs]

This should be tested. I am more curious than concerned !

[@juliahello6673]

Now do the Cybertruck 😳

[@tweetybird7668]

add in the bullet proof glass, scary during lake, river, pond recovery

[@mickeydongen]

their alloy is probably more fluid like than most castings

[@LouieGrind]

Jordan is extremely good at explaining manufacturing. A true talent!

[@marcbee1234]

I agree but a few more layman terms would be helpful for the lesser knowledgeable of us.

[@stevehamilton3181]

Ya but he needs to watch the jargon and acronyms

[@LouieGrind]

@@stevehamilton3181 In this day and age, if you really want to know what something means you can just Google the answer.

[@erklarkoala1004]

I really like your approach to sponsorships. I'm so used to just skip through the sponsored bits, but on Munro live you actually get a quick teardown of the advertised product. Props to that 👍

[@EugeneShamshurin]

As always thank you for the new installment of engineering eye candy!

[@MunroLive]

Thanks

[@GeeWit]

As much as I love Sandy, please keep cycling through Munro's deep bench of talent. All are good but some are great communicators like Jordan. As an interested generalist, I particularly appreciated the wind-up covering acronyms. Oh, and LoL Cory :: ...we are not KZbin engineers... 🤣 No shit...🤣

[@hardmack]

As with most of the internet, its a shame they even have to mention it, but there it is ;)

[@peterhelmer396]

Really awesome to watch rhe CEO of the company go to a stack af tool boxes to get a certain tool, and open the correct drawer on the first try! Tells me a lot about How Munro and associates operate their business!

[@richardwolf6269]

Or after the 5th take!

[@DetriotSteel]

That was some nice product placement😏

[@TheKevlar]

It was likely the first take! When he was removing the bolts his efficiency was superb...

[@RobbieFitzgerald]

@@TheKevlar I found it strange that he just throws the air ratchet on and goes to down. I always "crack it loose" first.

[@brianb-p6586]

@@RobbieFitzgerald that tells you that it was likely already cracked loose before this removal process was staged. That's okay with me - it's good theatre. 🙂

[@ManInTheBigHat]

It must be fun for Tesla engineers to watch these videos of Munro analyzing their work.

[@shannonwoodcock1035]

Between the structural adhesive on the body frame sections to the Pepto Bismo colored foam around the batteries. You know Tesla engineers are laughing their tails off.

[@carholic-sz3qv]

Lol…….

[@carholic-sz3qv]

@@shannonwoodcock1035 what’s particular about the adhesive!? It’s actually an automotive thing stfu!!

[@cathyk9197]

Also know that Tesla engineers are getting even more new ideas from watching Munro rip it apart!

[@w8stral]

@@cathyk9197 Uh, no they are not getting anything from MUNRO and Associates. Other companies might though. The engineers at TESLA like anywhere else, already have those ideas. Getting MANAGEMENT to get the F out of the way and ALLOWING them to do their ideas is the problem and has ALWAYS been the problem.

[@GOVAUS1]

The quality of that giga casting is exceptional. Good luck to anyone else who wants to mimic this. Great video from Munro. Thank you.

[@nitramluap]

The issue is whether they need to? If it can be created by one company, another company can easily do it... but they may have no need to so, particularly if they actually make more than 2 or 3 car designs. A single part like this could be a nightmare if it cracks.

[@userscott]

@@AudiTTQuattro2003 I think you’ve misunderstood the strength of these castings. It’s quite well understood and accepted by industry that anything likely to damage these castings will have, without doubt, caused a total loss in a conventional chassis. The point, however, is that this is a cheaper and quicker way of building a stronger body.

[@carholic-sz3qv]

Lol….. it’s actually super easy to make. Sport cars have been using those types of massive parts in combination with carbon fiber….. stop the crap!!!

[@carholic-sz3qv]

@@AudiTTQuattro2003 exactly! I’ll like to see how this type of casting survives on African or South American unpaved /bad roads! People really likes to praise tesla for what they do but totally forgetting that other companies have been making cars before them!

[@carholic-sz3qv]

@@userscott wrong!!!! The aluminum casting is brittle and can actually be damaged in a serious vibration/bump at critic speeds. Steel is much more stable

[@TheVineOfChristLives]

This is the only channel where a sponsor video review is actually quite interesting! interesting marketing strategy.

[@dr-k1667]

WOW!! All of that innovation in just 2 years! Just think how much faster it is to build the car now and this is just the body. Add in the ease of assembly to line workers when the seats are now mounted to the battery pack that is also structural and other refinements and part integration that haven't been revealed yet and it's easy to understand that Tesla is LEADING AND SPEEDING AWAY with this industry. Thanks for the information team Munro!

[@tribalypredisposed]

Love Tesla, but it is not really two years of innovation, it is seven. This is the version of the Model Y that Musk wanted to release, but the board overruled him and got the Model Y released without the 4680 cells and dual gigacastings and structural battery pack. But the first step Telsa took on this road was recruiting Jeff Dahn to lead their battery development team in 2015. The Gigacastings also were a long term project stretching back much longer than two years. And some of the companies Tesla bought for their technology, like the company with the dry battery electrode technology it had been working on for fifteen years, put more years of work into the innovation Tesla bought than Tesla has been making cars. The unbelievable vision and guts and depth of knowledge Tesla brought to the task of the Model Y with 4680 cells and gigacastings and a structural battery pack, assembling dozens of major innovations into one complete project, should stun and frighten every other automaker. The audacity to decide that you will be able to solve so many enormous problems in so many different technologies, and then to do it, is really incredible.

[@computercrack]

@@tribalypredisposed why should the other OEMs be afraid of this "giga casting" part? There are ups and downs to such a concept, it's not like anyone else wouldn't be able to do it, it's more like they didn't want to. Also I see some issues in general to this part. 1. They need to strengthen the strut dome with steel construction. Heavy, expensive and not necessary. The OEMs I know don't need shit like that these parts need to withstand much higher forces due to more weight. 2. The part he demounts is screwed AND spot welded. That's insanely dumb. Why would you ever want to do that? Either you weld it or you screw it down. Anyway, giga casting is nice and all but I do see a lot of good reasons to do it the old fashioned way.

[@tribalypredisposed]

@@computercrack they should be afraid because Tesla replaced 170 parts with two parts, eliminated 1600 something processes to assemble those parts, made the car assembly way faster and easier also by having a structural battery pack that they can mount the seats to and just lift up into the car body... All of those parts and processes required employees and robots and stamps and equipment and factory space that Tesla has greatly reduced, meaning Tesla has greatly reduced costs and time required for production. When the EV transition is done and EV production equals EV demand, cost of EVs will be a big factor in sales and Tesla will have lower costs. And the rest of the body is super stout because Tesla is very concerned about passenger safety in crashes, not because the gigacastings are inferior in some way structurally. In fact, the gigacastings plus structural battery pack make a far stiffer car body with the weight low and more towards the middle, improving handling on curves.

[@Thorshammer82]

@@tribalypredisposed it's rly musk's philosophy not to fear the Chinese copycats if Tesla moves so fast. Still impressive. The best thing for me: many of these new superior technologys will trickle down in cheaper products. From tesla or from any brand who copys this. But this will in the end bring the customer a real benefit. And not only serves for cost reduction in the company.

[@Lemon_Drums_USA]

@@computercrack the gigacasting makes production way faster. And way less expensive even with the extra welding and rivets

[@ExploringCabinsandMines]

The mold for that rear casting must be a work of art !!

[@randycarter2001]

I'm amazed at how much material is in these castings. Then to think that it was all done is less than half a second.

[@markplott4820]

the Gigacastings have LESS materiel than Traditional automotive UNIBODY construction. more than 50% less brackets , fastners and reinforcement.

[@Tom-ku8bu]

@@markplott4820 Yeah. But to press that much material in less than a second into the casting and cool it that it's stiff enough for the casting to open is amazing that that is even possible in such a short time

[@markplott4820]

@@Tom-ku8bu - NOT really that much materiel, the Gigacast is mostly Honeycombed with structural REINFORCEMENT and lighter than OLD unibody method , but is TOUGHER.

[@carholic-sz3qv]

Are you just dumb or what!! What is done in less than half a second!? Are you serious!?

[@carholic-sz3qv]

@@markplott4820 lol…… it also has zero repairability and for mods just forget about it!

[@simonthebroken9691]

Thanks for the Anker endorsement. I've been considering other brands as well. Your endorsement goes a very long way.

[@johnbuck971]

As a retired aircraft mechanic (primarily on helicopters), the fasteners, castings and adhesives have been used for many years. I am thinking a huge SpaceX influence.

[@eriktempelman2097]

Tesla is not alone in combining welds or fasteners with adhesives. BMW and others also use it in their biws

[@MrCarCrazy]

I guess we all see what we want to see. In my head it’s the influence from Lotus (who built the chassis/body of the initial roadster)

[@schrodingerscat1863]

These techniques have been used in the car industry for many tears now, look at any modern German car and the whole thing is held together with adhesives and rivets, very few welds now. Fasteners are only really there for alignment and to hold components together while the adhesive cures.

[@SamAlexCaldwell]

Hell yeah! I bought an Anker charger/battery set that came with a case back in early 2016. I took it on a ship for 4 years and used the battery literally every day. The set still goes with me everywhere, even though some of the USB ports have given up. Nice to see them getting the Sandi Seal of Approval.

[@Clark-Mills]

Munro YT is Munro's global marketing and recruitment department; all the while educating people who never realised how interesting the topic is. Well done guys!

[@OnigoroshiZero]

You ask if we get value from these? Your videos are gold mines. The expertise we see in these is outstanding, and the explanations for us are amazing. You guys are doing truly tremendous work here.

[@Frank_W.]

I foresee the Cybertruck tear down videos hitting the most views on this channel. The engineering genius of it will be fascinating to see. Thumbs up 👍 everyone!

[@JohnsmithQqqq]

That forward pillar is the heart of the passenger cabin strength in relation to the crush cans. The offset frontal crash tests I have reports on confirm this. As usual the Munro team always figure everything out. Great teamwork guys😊

[@jaydeister9305]

Wow! Great video! We've all been waiting for this super nuts and bolts breakdown of the car bodies! So from 172 stamped steel parts with 1600 robot spot welds, to two giga cast parts is epic engineering design (metals from scratch, millions of dollars in giga casting machines)! This subject, the Elon Musk/Tesla automotive design and engineering prowess should be in all engineering colleges (lessons learned/good vs bad vs worst)("great examples of success")("please don't ever do this, etc.")

[@TheRocky3211]

Great to see how it's all put together. I recently see the 22model y scored very well in crash testing

[@rogerstarkey5390]

Top of the class

[@carholic-sz3qv]

@@rogerstarkey5390 lol…… which class!? Wtf!!

[@VoxelLoop]

@@carholic-sz3qv Well, top of all classes. It had the highest score they've issued. (The test was of a 2022 Model Y by Euro NCAP)

[@VoxelLoop]

Just a side-note, the car tested by Euro NCAP is a 2022 Model Y but it will not have a structural battery pack and front casting like we nee in this video. Those are new features to the Texas built Model Y. The one tested by them will be a Shanghai or Berlin built with 2170 cells. :)

[@StefanSteinerWA]

Was that with a Model Y with gigacastings?

[@Marco_Dubbleyou]

I always think seeing your channel one thing really: you guys are serious but also having a laugh and a good time. That’s quite unique

[@ingmarkronfeldt6174]

If you really know your stuff, you can relax and enjoy the moment as well, right? It might also be that Monroe and Associates prefer to have people with expertise and humour (or humor if you find that more fun) on board, I guess.

[@lievenpetersen]

I appreciate Jordan taking the time to explain things to us plebs

[@christophmartin5381]

Always interesting, it never gets boring!

[@jbarvideo12]

Fabulous engineering design details provided by Cory and Jordan. Thanks for also explaining the acronyms. The video angles and closeups were especially revealling.

[@richardnedbalek1968]

Corey and Jordan: The “A” Team. 6:11 Corey makes every home mechanic envious with his mongo tool box, then uses his dress shoe heel to knock off a bracket. A man’s man! 👍

[@carholic-sz3qv]

Nope!!!!

[@gangleweed]

Those dress shoes were crash tested for kicking tyres a couple of hundred times without the heel coming off.....probably industrial adhesives play a big part in keeping the shoe together without visible stitching.

[@richardnedbalek1968]

@@gangleweed To be sure, they contain no threaded fasteners!

[@fred993a]

Cory and Jordan - Your analysis, with the help of your team, is spectacular.

[@robopilot7114]

Having worked as a mechanic on Airliners for over 30 yrs., I've applied adhesive on many parts as they are assembled. In Aerospace when parts are fastened together the sealant acts as a corrosion preventative(dissimilar metals), moisture ingress, fretting, and keeps fuel in the wings. The adhesive applied between parts is referred to as "faying surface sealant". We would joke about the adhesive being "structural" and the aircraft would definitely hold together if all the fasteners could be removed, although I wouldn't fly in it! That car is made to last decades before it will rust or fall apart!

[@tesla_tap]

And the castings are aluminum, so no rust!

[@MrAdopado]

@@tesla_tap ok ok ... corrosion ... aluminium certainly corrodes and weakens in different ways over time... but it should be a longer time than current construction methods/materials.

[@cratecruncher4974]

I'm an ME with years in automotive design and marketing. Obviously a catastrophic impact to any vehicle will result in a total loss. But the mind blowing disdain for field repair options in this body assembly gives me as a consumer real pause. While it's clever to save some weight and time on part complexity during the assembly process it leaves the consumer paying thousands in higher insurance premiums over the life of the vehicle. That's a gift that keeps on taking. Engineers need to consider the entire lifetime cost of operating the vehicle. Not just the first hours of assembly. It's a fact Tesla cars are far more expensive to insure than their competitors.

[@pnketia]

Another excellent breakdown guys! I like how detailed Jordan is with his explanations. Makes me wish I was an engineer in another life.

[@jtin217]

Looking great Cory. A visible difference from the Anker video insert. Thanks for the breakdown on the Model Y.

[@MunroLive]

Thanks James, down 45lbs from 2021.

[@437thx1138]

Munro, making engineering interesting every day

[@hikintrailsndrinkinales]

I love y’all educational contributions. Munro & Associates rocks!!!!

[@skeptick6513]

As a heavy collision tech whose repaired countless unibody structures by straightening and welding in replacement sections looking at this structure i cant imagine repairing much more than superficial damage unless Tesla allows for and supplies sub sections to allow partial repair of those castings. That being said it is revolutionary technology for car body fabrication. Looks like one of my old die cast toys.

[@1Snouser]

I feel like if a collision gets that deep and damages the gigacasting, the battery and whole vehicle are totaled at that point

[@tahderich]

It's basically throwaway design. one curb mount, one crash over 20 mph. one random hit and run of your parked car, one tbone and that car is gone. Then all that is left is to swap the un damaged ends between cars.

[@rogerstarkey5390]

@@tahderich Rubbish

[@skeptick6513]

Many cars can be struck frontally on the diagonal swaying the structure. Many times those collisions can be pretty easily repaired by pulling the structure back to position, a bit of stress relief and some minor metal work. Older Volvos were a favorite, those cars could get laid way over but pulled easily right back to place. Crush damage is more involved, often requires extensive metal work, cutting/sectioning or complete frame rail replacement but when you're working on higher value vehicles the insurance companies would put a lot in to a proper repair before writing off. My theory with Tesla is they arent particularly concerned about repairability, they will happilly sell you another car. I would not be surprised if they take an approach of insuring your car, fixing it if economical and if not they will take possession of your car, strip out the valuable hard parts (battery, running gear, computers) for their replacement business and crush the rest. Cradle to grave control and profits.

[@simonthebroken9691]

Thank you. Really amazing how much the castings simplify the vehicle.

[@PhiTonics]

17:40 Thank you! 🤗 He reads the comments!! Your the best Cory 👌

[@tcb333]

@Jordan, great job explaining in detail. I was able to follow you all the way through your thought process. Your keen observations are greatly apricated. In my experience it's rare to find an engineer who can also articulate engineering designs/concept to non-engineering audience. Equally rare is an engineer who know how to dress him/her self. Lookin' sharp buddy!

[@davedyer3654]

Model Y safest car on NCAP safety tests in Europe

[@cliffx7]

Jordan is goddamn Brilliant! This is the type of guy that I could have a conversation with for multiple hours without being bored

[@adamh1228]

Wow, those are some crazy castings. Reminds me of those huge light alloy forgings that revolutionized fighter aircraft manufacturing... minus the multi-thousand ton forging machine. I'd love to see the mold machinery and how they feed that stuff, I've run a bronze/brass foundry in the past, and that geometry is just unthinkable in the alloys I've worked with.

[@jamesdillon3320]

HEY GUYS!! I have worked with countless engineers in oil and gas over 35 years!! HOWEVER!! Young Jordan is very articulate and very well presented!! A very sharp young fellow!! GREETINGS from Canada!! GIDDYUP!!

[@jestrjk]

These videos are great, I hope you guys keep on keeping on with these things.

[@DarenYoong]

Tesla team should be very proud of their great work here! This is ‘pace of innovation’ as Tesla’s competitive advantage demonstrated. Not just the best, but the fastest. Thank you for this breakdown, Munro team!

[@joevandura9625]

Thanks Jordan and Cory! 💪 What a great insight into the item minimizing on the body of Tesla Y! It's amazing how hard they work on engineering the Struktur to reduce weight and costs! And it's also amazing what a great work you do to help us - the audience - to understand what, how and why! 👋👍👍👍❤️⚡🚗🙋🏼‍♂️

[@carholic-sz3qv]

It’s also amazing how they make those cars almost impossible to repair…..

[@joevandura9625]

@@carholic-sz3qv if you get any impact that destroys the castings, then a normal steel body would be smashed to the rear seats! Do you think you would repair a car missing the whole back? Including the half of the body containing the roof? The answer is no!

[@carholic-sz3qv]

@@joevandura9625 a normal steel body won’t be smashed to the rear seats stfu!!! The answer is yes and there are people like Arthur Tussik on KZbin that’s shows how it’s possible lol….

[@joevandura9625]

@@carholic-sz3qv Okay so you don't know how strong Teslas structure body is to a standard car... Sorry for you.

[@carholic-sz3qv]

@@joevandura9625 wtf do you call standard car!? Are you smocking something or what!? You think tesla is something unique!? Go educate yourself 🤡

[@mikaelbohman6694]

I love, love this second spring for Sandy and how he can monetize his deep knowledge and integrity like with the Anker endorsement ad. It gives me hope for the world.

[@budgetaudiophilelife-long5461]

CORY,JORDAN AND THE WHOLE MUNRO TEAM…🤗 WE WHOLEHEARTEDLY THANK YOU FOR SHARING ALL YOUR HARD WORK 😓 AND EXPLAINING TECH TERMS…. AND LOOKING 👀 GOOD 👍 THE WHOLE TIME 🤩🤩😎💚💚💚

[@MunroLive]

Our pleasure!

[@adepanko1289]

Fascinating and great presentation by Cory and Jordan. Great job!!

[@charleshaggard4341]

Wow, very impressive. Both the car and the team teardown and description of what we are seeing. Thanks

[@PatHaskell]

Very impressive, Jordan definitely knows his stuff!

[@GoatieDK]

Whatever Tesla did, they did right.... report just came out in Europe, that Tesla Model Y have made the al-time-high for NCAP score (highscore)

[@markplott4820]

2022 model Y EURO NCAP crash test Already done.

[@bbnlabs]

Yeah, but that's not the structured chasis. That's the regular Model Y. Not with the 4680 battery pack.

[@markplott4820]

@@bbnlabs - Correct , but TESLA is already TESTING manufacturing LFP, 2170, 4680, and RWD variants. IF, they decide to go into PRODUCTION , then they will SUBMIT samples for Testing.

[@bbnlabs]

@@markplott4820 the 4680 battery with structured pack is already in production. More than 1000 cars on the road in USA

[@carholic-sz3qv]

Lol……

[@dporrasxtremeLS3]

Outstanding team effort!!! Very interesting! Loved the built-in advertising too!

[@nobrien1]

Great job! I would love to hear some commentary about how the two giga-castings influenced body panel installation and alignment. Have they engineered misalignments out of the car?

[@markplott4820]

body pannels will now fit better with little variance.

[@betterwithrum]

I had an Ankur battery that I used for camping to run my CPAP machine... it started smoking before it cut off. Amazon took it back, I replaced it with an EcoFlow, I've never had a problem with it. No thanks Sandy, keep your seal of approval.

[@AntoineThisdale]

Its extremely impressed with the advancement in engineering made here. Great to see companies such as Tesla pushing the design and boundaries of industrial manufacturing. I have a bit of a concern, however. As the chassis design is being made with fewer and fewer pieces, made sturdier and faster, it helps production and average quality of each unit (and that should be obvious enough). But This also means that for most accidents involving deformation, the entire chassis needs to be changed. Soon it will be impossible to simple repair de car for minor damage. With this level of advancement (even counting the cost involved to develop), the cost of production should be going down and the price of the car/replacement should be going down... not up. I'm a Model3 owner and its an amazing piece of engineering, a joy to ride and use daily... but this does worry me.

[@richardmarshall159]

Would you anticipate challenges in accident damage repair and costs in light of unique front and rear casings with structural battery pac. Thanks, Rick

[@addictedtopiano]

I see Cory lost some weight - "lean design" indeed. :) And I also do appreciate the engineering since I've done physics and vehicle dynamics over my time.

[@jorgenr]

He looks 10 years younger than at the start of the series!

[@BjorckBengt]

06:15 I wonder if the spotwelding was done to get correct geometry, i.e. get the piece in the exact place before tightening the bolts?

[@brianb-p6586]

That makes sense to me. My guess would be that the bracket is held by a fixture (or robot) for spot welding, then the fixture gets out of the way while the spot welds hold the bracket for bolt installation. The welds do not appear to be structurally significant.

[@SUPERHEAVYBOOSTER]

The structural adhesive is really something.

[@markplott4820]

the BMW i3 was mostly Structural adhesive and Carbon fiber .

[@Resist4]

A repair nightmare.

[@carholic-sz3qv]

@@Resist4 totally! Yes a repair nightmare! I’ll like to see those cars in 10 to 20 years or in Africa trying to survive the roads there it’s going to be hilarious lol…..

[@carholic-sz3qv]

@@markplott4820 and recycled materials too which was way tooo advanced for its time.

[@dece6170]

This is nothing new, been used for literally decades in the car industry.

[@zencone]

Gotta love all the jargon and acronyms to keep the clueless among us clueless. But, it is nice to see Tesla continually iterating, now with the highest crash safety score of any vehicle ever in the new Model Y and yet still with room to improve on the child safety side.

[@goldreverre]

people concerned about non-repairability of castings... Being more rigid, it might have higher impact tolerance and be able to take a mild bump with less damage than stamped steel. Would love to hear a comment from Munro team on this.

[@ohger1]

You're correct. The casting is far more rigid and will not bend under the same conditions that a sheet metal assy willl - but it can crack, and it will take more than a "bump". An impact hard enough to crack the giga casting is assumed (at this point) to be sufficient enough to not only total the Tesla but in fact any conventionally constructed car as well. But, it's also speculated that cracks will be easily welded as long as there's no displacement, and of course as long as the rest of the body work/air bag costs don't total the car anyway. In other words, I believe a cracked casting will be the least of the trouble and perhaps the easiest and cheapest part to repair in a situation where an impact hard enough to crack a casting occurs.

[@Dularr]

They mention before it could be TIG welded. But I think in practice insurance companies are totallying Teslas.

[@blodg1]

Working in Tesla Collision my team has repaired many rear castings. The rail kit requires cutting off all damage and sectioning in a new rear rail with adhesive and several nuts and bolts. The result doesn’t look pretty but gets the job done.

[@FKS1994]

Any crash impact capable of breaking the casting to where it can't be repaired is essentially a totaled vehicle. An average car would be totaled regardless.

[@aussie_al]

Just wondering what people mean by totalled. Im from back in the day when we did cut and shuts to repair badly damaged front or rear. Its been a while now and im out of touch but is it law these days that a wreck can't be cut and shut???

[@Cybertruck_69]

Great video. You guys are really about the last hope for many OEM’s. That is good. We need engineering like you!

[@janholland2224]

Well done guys, job well done. Would be interesting (for a next time) to learn more on the C2C potential (cradle-to cradle). For some years it's been quite a problem for the steel industry to acquire good quality scrap. Is that aluminium or steel ready for the next product phase or .... ? What JB calls 'unmanufacturing' will become very important and you guys can to a certain degree define pathways for that industry ( consider tear-downs to be te artisanal phase of that industry ).

[@johnrussell5245]

A very important point.

[@gamerfromoldtimes8658]

Yet another course by wonderful experts on incredible technologies.

[@christopheredginton6242]

I bet Sandy would have have loved to be part of engineering innovation with Tesla if he could wind back time instead of all those wasted years with legacy auto that wouldn’t take notice of him and innovate when he had great ideas, although in a way he has helped Tesla as they have listened to him and implemented change. Love what all you do at Munro.

[@greggmcclelland8430]

He was. He gave free suggestions on the model 3 back to Tesla. They implemented a lot of his suggestions.

[@ChucksRover]

Super impressive, the car sure, but more importantly the team that Munro has doing these tear downs.

[@ConnectingODots]

How much should comparable parts weigh in a conventional build (including all fasteners etc)?

[@rogerstarkey5390]

Would be an interesting estimate. I bet it takes longer than a few Seconds to go from "raw material" to a cut, stamped, welded, bolted assembly of parts!

[@mpersad]

Another terrifically interesting and insightful video into the unique engineering that Tesla continue to produce . Great video, thank you.

[@JFabric500]

Fun to think of the castings from a Tesla insurance perspective. In most states if you get hit from behind it’s not your fault (As in if your car is totaled another persons insurance is responsible). If you hit someone else (car or person) it’s more than likely your fault and from the front (making it easier for Tesla insurance to fix and cheaper for them to insure)

[@WarrenLacefield]

Consider Tesla insurance from the manufacturer point of view. They need not reimburse at retail $$; rather they can just give you a brand new car (that they just made in 45 sec in their own factory at cost of production). No other insurance company can do that.

[@chrisbraid2907]

The difficulty you have in dismantling speaks to how well constructed the car has become. We understand how those bodies suffer during Dismantling which really only happens repeatedly in a Car body shop. For a one off operation you guys do really well …

[@NicoVeenkamp]

Thnx guys, I really love this show and tell of the rate of innovation that Tesla goes through and an illustration of Elon’s adagio that the best part is no part.

[@nahkanukke]

Using poprivets with threads on regular basis its a quite good fixing on 2-3 mm aluminum.

[@robertrjm8115]

The increased integration of structural elements into the castings is excellent and will have a very significant effect on cost reduction. However I think that the current designg is approaching a point of diminishing returns with respect to further integration and compexity in the giga castings where any more integration wil lead to more and more challenges in the assembly process having a negative effect on process effeciency. The geometric tolerancing and dimensionioning of course is strongly supported by the precission inherent in the castings and having the front and end geometry of the body defined by the castings will lead to perfect shut lines and fits. I wonder if the cross beam creating the roof line above the front window, which is currently made from pressed steel and apparantly has some small level of 'adjustability', would also benefit from a smaller casting.

[@celeron55]

Tesla will probably have already moved many of their engineers to other projects. No need to optimize further when it's taken this far already. They have many products coming in the upcoming decade and I would think Tesla aims to optimize them as far as possible before production starts.

[@oocares]

How repairable after a minor accident? Does this mean more cars will scrapped than fixed now?

[@othmanskn]

9:25, Jordan pointed out the disadvantage of these structural adhesives and batteries. More castings make the car rigid, so any shock energy will transfer to the passengers or cargo. A rigid structure may not even be as safe as pliant components that absorb impact forces, like the crumpling zones. Tesla must balance shock absorption to manufacturing efficiency.

[@Kenbark42]

@@oocares Cars with frame damage don't get repaired any more. Its totaled, because the time and resources required to repair any real significant impact is far more than the car itself is worth. Believe me when I say that if you get into an accident that is big enough to sustain frame damage you WANT it to be totaled. You don't want to be left with that mess of a "repair" and a salvage title. A total of the car is a best case scenario for you.

[@eliotmansfield]

inductive bolt heater would probably melt the adhesive in the threads and ease getting them out

[@chuckboyle8456]

Excellent video episode, thanks! Very informative. Is the “purple goop” the same as the battery pack industrial adhesive?

[@MrAdopado]

No.

[@louishiggins8881]

How repairable are these castings ? If they are damaged, does that mean the car is a write-off ? There are reports in the UK that car insurance for Teslas is skyrocketing because of the time and cost to repair 😢. Question for Sandy Munroe.

[@yoyomo777]

Aw, I thought castings was Sandy’s thing. You guys are great though 👍

[@rent2ownnz]

@4minutes. This a common and is called a Rivnut. hole is drilled, threaded rivnut is inserted (With Actuator and crimping thread pulling tool) and an either manual, Electro/Hydraulic or Air/Hydraulic Actuator pulls the hardened threaded insert to torque and then reverses the threaded insert. The other option is the bolt could be inserted with the part and a special tool designed to accept the bolt head can be inserted and pulled. You would definately need to have a 8.8 hardened bolt to pull the insert or the threads would pull out. you also need control the end pull up torque or the threads in the RIVNUT will pull out and strip. They are a very good fastener and you can also get Blind RIVNUTs ... so the thread is closed. This is to prevent corrosion of the bolt to allow ease of removal at a later date when the part needs to be removed. you can get these in Stainless 304, 304, normal steel and aluminium alloys as well.

[@shannonwoodcock1035]

I think you will see more detractors of Tesla's start chiming in about how relatively easy it is to total the car if in an accident? To me it comes down to how well does the car perform overall and how well does it perform in protecting its passengers in the event of an accident. The 2022 Model Y received a 5 star rating today from Euro NCAP Ask insurance companies, what ends up costing them more, the cost of the car or medical costs that need to be paid out?

[@markplott4820]

in a MINOR fender bender , the Gigacast is a IMMOVEABLE concrete slab , unaffected. IF, you are in a bad enough Accident to affect Gigacasting , its TOTALED anyways.

[@metriczeppelin]

Shannon, all cars are supposed to be engineered for ease of protection of it's occupants, not ease of repair. I understand your point, though. The vehicle is supposed to be the expendable component in the event of a debilitating crash, not it's occupants. Thanks and Cheers!

[@tribalypredisposed]

All of those people are also missing the fact that you will be less likely to get into a crash in your Model Y too. Especially once they have FSD, if you buy it.

[@camocamel3]

Did you see whistlindiesel cybertruck casting snap while towing? Thoughts?

[@MunroLive]

?

[@WarrenLacefield]

Very interesting! Lots of discussion around about recycling batteries, but with millions of Teslas on the roads (and getting older), seems to me that the question of how to recycle entire vehicles becomes more cogent. Think of all the aluminum and other "materials" in the car - so well made that the whole thing is like a huge brick. Is (or could be) the car designed in anyway for "recycling?" Does Monroe & Associates consider "end-of-life" issues in the tear-down reporting? I bet junkyards will sure have difficulties salvaging broken Teslas!

[@rogerstarkey5390]

Why would they have "issues" Turn off the isolator. Remove the battery (bolts) In this case, that includes the seats, etc, so great for putting into stock. Remove remaining interior, touch screen etc. Discharge the battery (they'll have methods to do that) either for stock, or call the battery recycler to pick it up (it's valuable!) . Doors, tailgate, frunk lid/ tray, body panels, lights, etc. . Other specific parts.... Then crush it...... Or shred it, depending on the machinery they have. What's the problem?

[@WarrenLacefield]

@@rogerstarkey5390 Thank you for a reply. Maybe there are no significant "issues" at salvage scale. But darn, one accident and you have an $80,000 "brick". (Like an iPhone, one bad drop and a $1,000 brick.) At least passengers are likely safer. Maybe with Tesla insurance (and raw-materials-in, new cars out, every 45 seconds, factories), the actual cost of full replacement might not be so bad.

[@rogerstarkey5390]

@@WarrenLacefield That's "one accident sufficient (as Cory said at 10:00 ) to render a "tradition frame" as a right off"?

[@ohger1]

@@WarrenLacefield You're missing the point. Any impact hard enough to crack a giga casting will total any car. Take a look at co-part and see relatively new cars that don't seem that bad but are totaled by the insurance company. Once the air bags go off, it's most of the way totaled anyway. The castings are most likely easily repaired by welding if they crack, but again, it comes down to the rest of the damage to the car.

[@WarrenLacefield]

@@ohger1 Ha, you guys are right - unfortunately (and maybe I am just reflecting my age). In the "good old days" ... most things about cars (even frames, etc.) seemed to be salvageable or reparable - expensive, but not so much as a new car. Nowadays, "parts" actually seem much better quality to begin with (good thing) and software updates stand in for a lot of that. But all that goes away in a serious accident. I would love to buy a Tesla ... but I have this trusty '95 Chevy Blazer 4w with 331,000 miles on it and still running just fine. 🙂Any part that breaks on it now costs more than the BBV. Couple more safe years, it will likely be "antique" - and by then Tesla will be on 4680, Motherboard 4, and FSD.

[@gutspraygore]

Of course the Munro team would dissect the sponsor. Ha! Great stuff as always. Thanks for sharing the video!

[@tomcastle7625]

I dont think those coils are for stray voltage. They are probably to reduce the high frequency harmonics from the switching thats happening on the A/C output.

[@jameshoffman552]

66.5 kg - mass of rear casting (also mine) GD&T - Geometric Dimensioning and Tolerencing PLP - Primary Locating Points Love the technical detail!

[@martinbusler7416]

I would love to see these advancements in the Model 3.

[@markplott4820]

coming to MOD 3 in Fremont in 2024 after RAMP of GigaAustin. GigaChina slated for UPGRADES also in 2024, mabye sooner.

[@rkan2]

@@markplott4820 How about Berlin?

[@markplott4820]

@@rkan2 - BERLIN , already test production of RWD (domestic), 2170 , LFP and 4680. Berlin already selling MIC mod Y w/ RWD.

[@rkan2]

@@markplott4820 What you mean by domestic?

[@markplott4820]

@@rkan2 - made in Germany , not imported from China.

[@deanedonaghy243]

They have engineered these cars to be throw away items if they ever suffer a moderate crash which might crack, or distort the sub assemblies. Just the labor costs alone would make them insurance write off's which just make them more expensive to insure, which is becoming an issue with some insurers today because of the various issues that plague EV's.

[@brddukaty7460]

Great job

[@klauszinser]

I (we) really have to admire Munro & Associates for the risk of taking all the expenses for the vehicle (which unfortunately had to get destroyed for the better good), the work taking it down to components and the expertise of the People working at Munro letting us know how tremendous work Tesla has done. Also a big thanks to the sponsors. It reminds me of the car manufacturing especially after WW2 which was heavily influenced (even later) by the plane engineers and industry. Well, not it seems they get a lot of knowledge from the Space Industry (SpaceX). But also the risk taking approach to improve products. Because of this young people are attracted to become engineers. Its good to see how a more than 100 year old industry can be improved. well, it has to be mentioned, a lot of this creative destruction (Joseph Schumpeter) comes from outsiders, people who have not been working for the car industry before.

[@stephencampbell9095]

4:00 Rivet looks more like a huc-bolt to me.

[@rgeraldalexander4278]

Model Y is such an innovative approach to automobile construction...thanks for sharing!

[@take5th]

As a former structural design engineer in aerospace during the 20th century, I am blown away by those casting. Would have to see the material properties to know more, but far beyond any complexity I’ve seen in that field. Castings not used in aerospace during my time main;y because the Elon-gation properties were insufficient. (little joke there) for all load and failure modes. Cars are different, but wonder if aerospace these days is using anything similar.

[@terryhalsteadgamer]

I heard Sandy say in a previous video I think on the Bolt that the majority of aerospace is all about carbon fiber now.

[@rogerstarkey5390]

It's a work of art, isn't it?

[@mbox314]

Wouldn't aerospace just use investment casting as opposed to die castings?

[@reyyannajeeb1067]

Apparently there is a materials guy that works at both SpaceX and Tesla. There was some cross pollination there to get this material correct

[@mickeydongen]

they got some space engineers working at Tesla bruuhhh

[@FelixTheCat69]

Hey guys, just ordered the Anker backup UPS/battery. Don’t forget to mention that it delivers pure sine wave power AND is a UPS. This is a steal for the price. Thank you for the promo code

[@Yoshi-wo1do]

if there's damage far enough into the vehicle to impact the castings the car is most likely totalled anyway

[@rgeraldalexander4278]

Yep, no difference from any other car in that respect, and Teslas are safer, so injury claims should be lower.

[@eriktempelman2097]

Underappreciated benefit: lifetime. Regular spot welded steel bodies slowly come apart, as the welds break one by one. Every joint is a potential fatigue problem. With this kind of integration, it's different.

[@Engineersoldinterstingstuff]

Repairability..? Otherwise the insurance cost of these vehicles will be ridiculously expensive.

[@sw8681]

I think that's part of what the "crush can" portion is about; shock absorption and reparability. My guess is that if you are in an accident that seriously damages the casting beneath the crush can, the accident is serious enough that repairing the vehicle is less of concern than survival.

[@Engineersoldinterstingstuff]

@@sw8681 A normal person needs to survive both physically and economically...

[@mikereliford55]

I love the debut of the Packout stack!

[@surferdude4487]

Sandy likes to call threaded fasteners "unfasteners". What does he have to say about it when there is structural adhesive poured into the threads? Eliminating parts, eliminating tolerance stacks, eliminating fasteners... Is anyone else pursuing excellence the way Tesla is? I do not think so.

[@patreekotime4578]

To be fair, of major automotive manufacturers, Tesla is in an extremely unique position of not having "heritage" body shops running for 60 years and slowly updating. As a startup, Tesla was able to make the decision very early in the history of the company to do iterative improvements. For any legacy manufacturer, doing iterative improvements would not only mean completely changing how they build cars, it would mean throwing away alot of legacy hardware and parts bin parts that they use to help control costs. It is a VERY expensive upfront cost to make these kinds of changes that would require approval up the chain of command and finally with the major shareholders. In an industry that has spend GENERATIONS trying to nit-pick to control costs, often in counter-intuitive ways, the idea of spending a ton of cash up front to save money down the road just doesnt mesh well with how corporate accounting typically works.

[@Elemblue2]

@@patreekotime4578 Thats why competition is important. Motivations gotta come from somewhere.

[@patreekotime4578]

@@Elemblue2 Yup. Complacency has been the name of the game for too long. Although Ford doing the aluminum F150 was pretty ballsy, it will be interesting to see what happens now that the guantlet is thrown down... Although one thing seems for certain, workers in body shops should be very concerned about their job security.

[@surferdude4487]

@@patreekotime4578 To be really fair, Sandy has been trying to get the auto manufacturing industry to move in this direction for two generations now. The sad truth is that the non-engineers that have been in charge for far too long and will get their golden parachutes no matter what happens, are responsible for this lack of progress. It makes me burn that the rotters responsible for this mess will get to retire in wealth and luxury while the poor slobs that work on the line will lose their livelihood.

[@brendandonegan2150]

In the UK, I can't speak for mainland Europe, the cost of insurance premiums for Teslas, compared with cars of similar cost, has increased substantially year on year. It is generally understood that this is due to the high cost of crash repairs and the low write-off threshold. Your excellent video removes any doubt as to the situation. Should repairability and the concomitant insurance burden on owners not be given weight when designing for passenger safety and manufacturing cost efficiency? There is also the question of recycling parts from major repairs or written-off vehicles.