How the Tesla Model S is Made | Tesla Motors Part 1 (WIRED)

Summary

The video takes an in-depth look at the innovative manufacturing process behind the Tesla Model S. It begins with raw materials like coils of aluminum, which are processed through various stages, including blanking, laser cutting, and pressing. The body is assembled using five joining methods, and advanced robots assist in painting, assembly, and installing components like seats and windshields. Tesla’s approach blends automation with design innovation, resulting in a highly efficient production system. The factory represents a futuristic vision for manufacturing, with rapid production timelines and a focus on continuous improvement.

Takeaways

• 😀 The manufacturing process of the Model S is unique and different from other cars, starting with raw materials like aluminum coils.
• 😀 The aluminum coils are uncoiled and cut into flat pieces, known as blanks, using special machines and lasers.
• 😀 The flat pieces are then fed to press lines, where gigantic dies are used to form the vehicle's body panels.
• 😀 After the body parts are formed, they are brought to the body shop to be assembled into the car's body shell.
• 😀 The body shop uses five different joining methods: adhesive, self-piercing rivets, cold metal transfer, conventional resistance welding, and delta spot welding.
• 😀 Once the body leaves the body shop, it is a completed shell ready for painting, which involves multiple automated stages like primer, base coat, and clear coat.
• 😀 Robots are heavily involved in the assembly process, including the use of 'smart carts' that move the cars along a magnetic strip for efficient assembly.
• 😀 Versatile robots are used in the production line, including one robot that handles multiple tasks, such as installing seats, windshields, and rear glass.
• 😀 Tesla focuses on in-house production for most of the stamping panels, with engineers present at the facility for quick design and iteration.
• 😀 The entire process from raw materials to a finished Model S takes approximately three to five days, showcasing the speed and efficiency of the production line.

Q & A

What is the first step in the manufacturing process of the Model S?

The first step involves uncoiling coils of aluminum of different gauges and types. These coils are flattened and cut into flat pieces called blanks using a blanking machine.

What technologies are used in the blanking process?

In addition to traditional blanking tools, the process utilizes lasers to cut and shape the aluminum pieces into blanks.

What happens after the aluminum blanks are created?

The aluminum blanks are fed into press lines with gigantic dies that form the panels necessary for the body of the vehicle.

What is the role of the body shop in the manufacturing process?

The body shop assembles the various stamped panels, bringing them together at one central location. It starts with the underbody, then moves to body sides and the front end of the car.

How is the body of the Model S put together?

Five different joining methods are used: adhesive, self-piercing rivets, cold metal transfer, conventional resistance welding, and a new delta spot welding system.

What happens to the body after it leaves the body center?

Once the body leaves the body center, it is fully assembled and ready to be prepped and painted.

How is the painting process carried out?

The body is placed into a conveyor system and moved to the paint shop. Robots perform multiple stages, including pre-treatment, primer, base coat, and clear coat, in a clean environment.

What makes the assembly process of the Model S unique?

The assembly process is highly automated, with robots playing a significant role. The car moves through the factory on a magnetic strip, and different robots handle various tasks, including installing seats and windshields.

Can you explain the versatility of one specific robot in the assembly process?

One robot is used for multiple tasks: it handles seat installation, applies glue for the windshield, and installs both the windshield and rear glass. This shows the robot's adaptability and efficiency.

What is the current time frame for manufacturing a Model S from raw material to completion?

It currently takes about three to five days for a Model S to go from raw material to being finished on the assembly line.