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Tesla has achieved a breakthrough in making Hot Wheels-like single-piece car casting a reality, according to a new insider report.

In recent years, Tesla has heavily invested in large casting technology to produce vehicle bodies in just a couple of large parts rather than hundreds.

The automaker now operates several of the world’s largest casting machines, which it often refers to as “Gigapress.”

CEO Elon Musk has often referenced how he has been inspired by Hot Wheels toy cars being made in a single cast piece and hinted that he would like Tesla cars to eventually be made like that.

However, Tesla has already pushed the limits of casting technology to be able to produce the rear and front casting on Model Y and had a new 9,000-ton press made to produce Cybertruck parts.

But now a new report claims that Tesla has achieved “a series of innovations to make a technological breakthrough” to “die cast nearly all the complex underbody of an EV in one piece.”

The report is coming from Reuters based on “five people familiar with the move”:

The five people said a single large frame – combining the front and rear sections with the middle underbody where the battery is housed – could be used in Tesla’s small EV which it aims to launch with a price tag of $25,000 by the middle of the decade.

However, the report claims that Tesla has not yet decided to use the new technology for its next-generation vehicle, but it could make a decision as soon as this month.

Reuters claims that one of the innovations involves using 3D printing and industrial sand to create the molds for casting, which can cut the cost and time it takes to make inevitable modifications to the molds:

To overcome the obstacles, Tesla turned to firms that make test molds out of industrial sand with 3D printers. Using a digital design file, printers known as binder jets deposit a liquid binding agent onto a thin layer of sand and gradually build a mold, layer by layer, that can die cast molten alloys.

The report mentions Tesla using Desktop Metall’s ExOne machine.

Another innovation is through material science. The report states that Tesla faced issues with having an alloy that works both with the 3D-printing process of the mold and the performance and safety requirements for a car, but the company has made progress:

The casting specialists overcame that by formulating special alloys, fine-tuning the molten alloy cooling process, and also coming up with an after-production heat treatment, three of the sources said. And once Tesla is happy with the prototype mold, it can then invest in a final metal one for mass production.

Tesla has a strong material science team that it shares with SpaceX, and it has already designed several new alloys used by the two companies.

Finally, the report also mentions that Tesla hasn’t finalized plans for a new bigger Gigapress needed to build those large single unibodies.

Electrek’s Take

Tesla fans like to criticize Reuters for publishing misleading negative reports about Tesla, and there’s definitely validity to the criticism, as we highlighted in a recent report.

However, in this case, Reuters published a very detailed report that makes sense based on Tesla’s plans.

We know that Tesla has been working on such a technology since before the Model Y came to market, and Elon Musk briefly pushed for more innovation in the electric crossover’s platform before backtracking a bit in favor of bringing it to market faster.

Tesla had an interesting patent on that technology back in 2019.

I still think this should be taken with a grain of salt, but I wouldn’t be surprised if it turns out to be true.

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Porsche’s EV sales took a hit last year, but the electric Macan sparks hope

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Porsche's EV sales took a hit last year, but the electric Macan sparks hope

Although sales of Porsche’s first EV, the Taycan, fell nearly 50% in 2024, things could be looking up for the sports car maker. After its “launch literally electrified us,” the electric Porsche Macan may spark a comeback this year.

Why did Porsche’s EV sales drop in 2024?

Porsche delivered over 310,700 vehicles globally last year, or about 9,500 less than in 2023. Sales in China led the downfall, plunging 28% from the prior year amid a wave of low-cost domestic EVs entering the market.

In total, Porsche delivered 20,836 Taycan EVs to customers last year, down 49% from 2023. The lower total comes after launching the upgraded 2025 Taycan last year. Porsche also said, “The ramp-up of electric mobility is generally proceeding more slowly than planned” as part of the reason.

In its largest sales market, North America, Porsche delivered over 86,500 vehicles in 2024. Although that’s up a mere 1% from 2023, Porsche’s EV sales also took a hit.

Porsche sold 4,747 Taycan models in the US last year, 37% fewer than in 2023. The 2025 model began arriving at US dealerships last Summer, which helped push sales up nearly 75% in the fourth quarter to 2,358.

Porsche's-EV-sales-2024
2025 Porsche Taycan (Source: Porsche)

Meanwhile, Porsche’s second EV, the electric Macan, could have an even bigger impact. After delivering the first models at the end of September, Porsche delivered 18,278 electric Macans by the end of 2024.’

“This launch literally electrified us. I am therefore particularly pleased that more than 18,000 examples of the all-electric variant have already been delivered,” Porsche AG board member for sales and marketing, Detlev von Platen, said.

Porsche's-EV-sales-2024
Porsche Macan Electric (Source: Porsche)

Porsche sold 2,771 electric Macan SUVs in the US last year. On a call with reporters (via Automotive News), the company’s North American CEO, Timo Resch, said, “A lot of the consumers that come into the Macan Electric are [new to the] brand.”

Electrek’s Take

I’m not here to say the electric Macan will be Porsche’s savior, but the strong sales start is promising. Porsche has already backtracked on plans for 80% of deliveries to be electric by 2030.

According to recent reports, the electric Cayenne, due out in 2026, could be delayed depending on market demand. The upcoming 718 Cayman and Boxster EVs could also face delays as Porsche plans to keep gas and hybrid models alive longer than expected.

Looking ahead, Porsche also plans to introduce an ultra-luxury electric SUV to sit above the Cayenne, codenamed “K1” internally. It’s expected to compete with Range Rover and Ferrari’s first electric SUVs.

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Elon Musk complains Tesla is not getting subsidies for electric truck chargers while calling for end of EV subsidies

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Elon Musk complains Tesla is not getting subsidies for electric truck chargers while calling for end of EV subsidies

Elon Musk complains that Tesla is not getting subsidies for its electric truck chargers while calling for the end of electric vehicle subsidies in the US.

Earlier this week, the Biden administration released the last round of funding for electric vehicle charging stations before the President leaves office.

Tesla has been trying to secure part of that funding for its TESSERACT project, which was first announced in 2023 to create a corridor of 9 charging stations for electric trucks between California and Texas.

However, it wasn’t included in any round of funding, including the latest one announced this week, which should be the latest now that Trump is getting into office and campaigned on ending electric vehicle subsidies.

Tesla CEO Elon Musk contributed more than $240 million to get Trump elected and supported his goal of removing subsidies for electric vehicles.

That’s why it’s surprising to see Musk comment on the news in disappointment. He wrote on X: “Hear we go again (sigh)”.

While this specific project wasn’t funded, 49 other projects shared over $600 million in funding that will deploy more than 11,500 EV charging ports across 27 states, four federally recognized tribes, and the District of Columbia.

Also, while Tesla didn’t get any funding in this round, Tesla has received millions in funding for its charging stations in the previous round.

Electrek’s Take

I think that’s fair. If you are actively lobbying for the end of EV subsidies in the US, a market that is far behind the rest of the world in EV adoption, why should the administration that is investing in correcting that give you the subsidies you are trying to end?

It makes no sense. That’s why I also support California in signaling that if the Federal government removes its EV subsidies, it will replace them at the state level, but Tesla will be left out.

It’s especially fair considering Elon has made it clear that the reason he wants to kill EV subsidies, which Tesla was the biggest beneficiary of, is that he believes it will put more pressure on the competition than Tesla and potentially kill them while only Tesla will remain.

He basically wants to pull the ladder that Tesla used to get where it is now to prevent others from using it.

“Subsidies for me, not for thee” – Elon’s new motto.

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New York is now coming for your fast and heavy electric bikes

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New York is now coming for your fast and heavy electric bikes

The US electric bike industry has already seen a regulation-heavy start to 2025. Now, New York Governor Kathy Hochul’s potential new restrictions on fast and exceedingly heavy electric bikes could add to the proposed and enacted legislation we’ve seen lately.

Hochul proposed in her State of the State address yesterday that Class 3 electric bikes weighing over 100 lb (45 kg) be excluded from existing electric bicycle regulations and instead be treated more like mopeds.

That would mean imposing motor vehicle regulations resulting in licensing and registration requirements, as well as disallowing their use in bike lanes.

The governor explained that this new regulation would ideally help increase the safety of bike lanes, according to Streetsblog NYC.

wallke h6 electric bike

As a reminder, Class 1 and Class 2 e-bikes can reach a top speed of 20 mph (32 km/h) on motor power, with Class 2 e-bikes including a throttle that allows motor use without requiring the pedals to be used. In most states, Class 3 e-bikes can reach higher speeds of up to 28 mph (45 km/h) with pedal assist but not throttle. However, New York State has stricter Class 3 limits that provide for speeds up to just 25 mph (40 km/h).

The proposed new regulations would only target Class 3 e-bikes that exceed the suggested weight limit of 100 lb (45 kg).

Most electric bikes weigh well under 100 lb (45 kg). Common e-bikes seen regularly on US streets and bike lanes weigh between 50-75 lb (23 to 34 kg). However, there are some e-bike models available on the market that can reach or exceed 100 lb (45 kg). We’ve tested a few of them.

Such heavy electric bikes are usually visually similar to mopeds and light electric motorcycles, often featuring large tires, heavy motors, dual suspension, chunky frames, and other components that add significant weight. However, many heavy electric bicycles are limited to 20 mph (32 km/h), and could exceed the arbitrary 100 lb (45 kg) proposed limit while still not falling under this proposed regulation due to their Class 2 designation.

Dual motors, dual batteries, extra chunky, but still under 100 lb

Electrek’s Take

At face value, there’s some logic to this. A 100 lb electric bike has a lot more rolling mass than a 50 lb electric bike, and you can guess which one I’d rather get hit by. Though at the same time, when the rider nearly always weighs more than the vehicle, the weight of the e-bike certainly has a lower relevance to its safety. With a 200 lb (91 kg) rider on both bikes, we’re only talking about a relatively small 20% difference in mass.

And it’s a bit telling that there wasn’t much discussion in the State of the State address about any other road safety issues, certainly not about the several thousand-pound cars that actually kill many New Yorkers every year.

I’m not saying I don’t support reasonable regulations to ensure the safety of everyone, in the bike lanes and outside of them. But let’s get real here. The percentage of electric bikes that are 100+ lb is tiny, likely under 1-2% of all e-bikes on the road. And that’s a tiny slice of an entire pie that is itself a tiny slice of the injury-causing-vehicle pie. So I’m not saying there isn’t any good regulation opportunity out there for e-bikes. But this is all fluff on top of fluff if you think it’s actually about making a meaningful impact on road safety. If they really cared about better protecting cyclists, governments would enforce existing laws to prevent cars from killing them so frequently.

These types of clumsy, heavy-handed regulations are just that – quick and dirty attempts to appear to be working towards a solution, when in fact they are largely meaningless in their ultimate impact on protecting lives.

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