Demystifying Tesla‘s 2170 and 4680 Batteries

As Tesla continues leading the global transition towards sustainable transport, much credit goes to their in-house battery R&D pushing the boundaries of EV range, performance and efficiency. Tesla currently leverages two major lithium-ion battery types across their model lineup – the 2170 cell and the new 4680 format.

So why does Tesla use different battery designs? How exactly do the 2170 and 4680 compare? Read on as we demystify Tesla’s tale of two battery platforms!

Why Tesla Developed The 4680 Battery Cell

First, some quick history before analyzing 2170 vs 4680 specs…

Tesla and their battery partner Panasonic started mass production of the 2170 cell in 2017 for the Model 3 rollout. The 2170 soon became Tesla’s workhorse battery format powering Model 3, Model Y and even grid storage products.

But Tesla realized that despite advances, lithium-ion batteries remained inadequate for affordable long-range EVs. Constraints around energy density, charging speed, production costs and mineral usage needed breakthrough disruption for EVs to truly replace gas-powered cars across all price segments.

Thus Tesla engineered the 4680 – a bigger, bolder battery design enabling their 3 Tera goals:

🔋 Terawatt-hour scalability: Radically simplify manufacturing to allow rapid gigafactory expansion

🔋 Terawatt vehicle production: Reduce $/kWh cost + complexity allowing mass market EVs with higher margins

🔋 Terawatt battery outputs: Enable step-function improvements in critical metrics like range, charging speed and power

Essentially, the 4680 battery has been optimized right from the drawing board to fast-track Tesla’s next S-curve of growth.

Now let’s analyze how the 4680 cell aims to deliver on those promises by comparing its specs versus the older 2170 format…

Dimensional and Functional Differences

You can observe the 2X-5X functional density improvements by simply switching scale and internal geometry. Combine this with simplifications enabled by vertical integration, and you get the financial recipe powering Tesla’s Tera ambitions.

In essence, the 4680 enables:

🔋 5X energy capacity (range)

🔋 5X power output (acceleration)

🔋 6X faster charging

🔋 5X production output

🔋 50% lower $/kWh cost

Now that’s what we call an upgrade!
Next let’s analyze how different model lines harness 4680 capabilities…

Models Equipped With 2170 vs 4680 Cells

As of late 2022, here is the status on Tesla vehicles featuring 2170 vs 4680 battery types:

A few key insights on the transition timeline:

• Model Y’s from Gigafactory Texas already feature 4680 structural packs with front and rear megacasts
• Model 3 will move to 4680 format later down the road
• Next gen vehicles Cybertruck and Semi will introduce 4680 batteries to customers
• S and X models will also switch when redesigned on new platforms

Bottomline – all battery electric platforms launching in 2023 and beyond will leverage 4680 cells. With Model Y projected as Tesla’s highest volume program, 4680 production capacity needs to ramp exponentially.

Speaking of manufacturing scale, let‘s analyze an often overlooked driver powering Tesla‘s capacity growth…

Manufacturing Innovations – Vertical Integration

Tesla Battery Day dug deep into proprietary process innovations enabling their capacity leaps:

1. Dry Electrode: Eliminates wasteful, time-intensive steps of wet coating that constrain cell makers like Panasonic:

• Allows thicker electrodes for higher energy density
• Enables 70% faster line speeds while loweringcapex spend
• Sustainable process using zero hazardous solvents

2. Cell-to-Pack: Connecting cells directly into pack format sans separate modules simplifies assembly while improving design flexibility

3. CATL-Inspired Sodium Chemistry: Advances cell chemistry by eliminating expensive Cobalt use, improving performance, lowering costs

4. Maxwell Acquisition: Dry battery electrode tech (above) acquired along with ultracapacitor product/IP

5. Hibar Acquisition: Battery manufacturing equipment maker supports custom tooling optimized for dry electrode and tabless cell processes

What does vertical integration really achieve here?

1. Relief from third party constraints or bottlenecks
2. Protect proprietary techniques providing sustaining advantage
3. Achieve performance gains unviable for commercial suppliers
4. Leverage custom platforms as competitive moat for products

Let’s see how these unique process innovations manifest into owner experiences…

Real-World Validation and Ownership Experience

Still own one of the early 4680 Model Y editions delivered in early 2022? Congrats, you’re part of history! 😄 Early owners and YouTube reviewers have validated remarkable performance benefits unlocked by the 4680 structural pack architecture and clean-sheet design:

• Sub 3 Second 0-60 MPH: Despite being AWD LR models, 4680 Model Ys clock 0-60 MPH timings competitive against Performance variants! Even roll-on acceleration and torque feel stronger compared to immediate thrust in 2170 LR models.

• 200+ Mile Recharges: Charging data indicates 4680 Model Ys gaining 200+ mile ranges from 15 minute Supercharger sessions. That works out to >800 miles per hour effective charging rate! For context, the 2170 Long Range peaks under 500 miles per hour typically.

• 10-90% in ~25 Minutes: Multiple owners have posted Plaid-mode charge sessions demonstrating 4680 Model Ys regaining 180+ miles in under 25 minutes

• 330 Mile EPA Range: Official EPA test cycles reveal a 12% bump over 2170 LR variants thanks to cutting-edge aerodynamics, chassis and powertrain efficiency

Clearly the early data backs up Tesla’s claims on the 4680 format delivering step-function improvements in acceleration, charging and range metrics. And we’re just getting started here!

The Road Ahead

While 4680 production volumes remain limited as of early 2023, Tesla aims to exponentially grow annual capacity to over 100 GWh in the coming years across Fremont, Berlin, Austin and beyond.

Here is a realistic roadmap for scaling 4680 tech dominance:

2023:

• Texas Model Y annual production grows 6X to ~500K units
• 4680 structural packs + front/rear mega casts ramped up
• New model launches to use 4680 batteries (Cybertruck, Semi)
• Panasonic 4680 line qualification and production

2024:

• Model Y Fremont plant transitions fully to 4680 batteries
• Berlin factory starts regional Model Y production at scale
• 4680 pack production capacity grows 6-8X YoY

2025-2026

• Model 3 transitions fully to 4680 battery packs
• Model S and Model X next gen models move to 4680 + structural architectures
• 4680 production capacity grows 2-3X YoY
• 100 GWh+ annual capacity across regions

2027+

• 4680 tech and process innovations propagated across energy storage products
• Continued capacity expansion as required while reducing regional cell production redundancy

Note that the lightning pace of manufacturing innovation continues in parallel – we should expect radical battery tech and chemistry advances from Tesla throughout this decade.

The competition, meanwhile, faces a mammoth challenge attempting to replicate Tesla‘s vertical structure, cost base and institutional skill concentration. Few besides maybe BYD have the ingredients at scale to internally drive leading edge progress merging battery tech with automotive-grade innovation.

So while rivals aim to just propel their EVs forward, Tesla is poised to accelerate while increasing range through unconditionally better technology.

Key Takeaways – 2170 vs 4680 Batteries

Let’s recap our top learnings on Tesla’s two signature battery platforms:

1. The 4680 battery incorporates 5 key innovations: Tabless design, dry electrode coating, high-capacity nickel chemistry, cell-to-pack integration and extreme high-speed production.

2. These process improvements manifest into 5X better functional performance – energy density, power density, charging speed, production volume and lower cost.

3. Model Y is the pioneer for 4680 adoption today with all Gigafactory Texas builds featuring the new cell format. Model 3 and semi/Cybertruck down the road…eventually all Tesla products.

4. 4680 packs deliver measurable real-world gains verified by early owners – 300+ mile range, sub 3 second 0-60 MPH, 200+ mile 15 minute charging, and more.

5. Vertically integrated manufacturing is Tesla‘s secret weapon for protecting process innovations while scaling capacity.

So in summary – when comparing 2170 vs 4680 batteries for Tesla‘s products, the 4680 is hands-down superior for performance, production and strategic power. As Elon Musk promises, Tesla Battery Day was all about explaining three Tera scale ambitions to fundamentally transform electric transport economics through ground-up battery innovation.

The 4680 serves as lighthouse for that next S-curve of growth. Exciting times ahead…let‘s see if competitors can keep pace!