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Tesla 4680 Battery Cell: Solving the Silicon Nanowire Expansion ProblemTechnical deep-dive into Tesla's 4680 battery cell design, focusing on silicon nanowire anode technology and mechanical stress management during charge cycles.
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Tesla's dry electrode process eliminates solvents but has struggled with uniformity and adhesion at scale. Can they solve these manufacturing challenges?
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The dry process works in lab settings but achieving consistent powder distribution and adhesion across large electrode sheets is proving difficult. Traditional wet processes have 50+ years of optimization. Tesla's betting the company on solving this in <5 years.
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Drew Baglino•VP of Powertrain & Energy Engineering, Tesla
Drew Baglino•VP of Powertrain & Energy Engineering, TeslaResponses (1)
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Drew Baglino
•VP of Powertrain & Energy Engineering, TeslaThe dry electrode process is Tesla's biggest manufacturing risk. Traditional wet coating has decades of process optimization. Tesla needs to solve powder distribution, adhesion uniformity, and porosity control simultaneously. They're making progress but it's taking longer than projected. The cost and energy savings are massive if they solve it - 50% manufacturing energy reduction and eliminating toxic NMP solvents.