How the Tesla Model S is Made Tesla Motors Part 1 WIRED




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for me manufacturing steinberg the way we assemble this car the way we put it together all of this is essentially very different from another cop the modernist process stages is all starts with raw material we have coils of aluminum different gauges different types of aluminum maybe 56 equals [Music] we start the process by uncoiling the coils in a special machine we call blanking machine that allows to flatten the metal person and cut it into fat pieces we call them blanks in addition to traditional blanking tools were using laser and then with these species we feed them to the press lines his gigantic dies and the press lines essentially form the panels you know boom [Music] we're getting all of the parts necessary to meet the body of the recall out of those gigantic machines and then all of these parts as they are finished so to speak are brought to the body shop the [Music] rule of the body center is to take all the stamping panels that we make and we bring all that together in one central location and that's where we actually put the model ass together we'll start and we do an underbody which is the main floor system of the car and then from there we'll move to body sides that's the internal reinforcement as well as the outer skin and inside the framing area we take the body sides the underbody and the front end of the car and we actually marriage it all together [Music] one of the most unique things about this body center is we actually have five different overall joining methods for the body show we use adhesive we use self piercing rivets we have cold metal transfer conventional resistance welding as well as a new Delta spot welding system when a body leaves the body center it's actually a full completed body shell ready to be prepped and painted every gigantic robot that takes the body and put into an conveyor it is conveying to the paint shop you have multiple pretreatment primer base coat clear coat all of this is supplied with robots that have a special ability to paint in a very clean environment you get a beautiful painted body that's coming to general assembly where we have these super elegant robots we call smart card where every card is essentially moving through the factory by itself it follows a magnetic strip and essentially the card is being assembled from inside out [Music] we're utilizing automation to the fullest we have a variety of robots from the teenager ones to huge one that are able to move the entire body itself [Music] one of the robot that I I'm always very impressed to look at is the one that puts the seeds inside a Model S and the same robot is able to change tools go from a seat handling device to putting the windshield actually grab the windshield put some glue around it and then put the windshield onto the car as well as do the real glass of the vehicles so talk about versatility here we have most everything we need right here in house we do the majority of our stamping panels ourselves we have design engineers here at the facility so we're very nimble and very quick at what we do currently it takes about three to five days for model has to go from raw material all the way to being finished on the air vent line it's magnificent it's like a piece of art we constantly try to improve process efficiency we want to push the boundaries of what can be done by robots versus humans so it's a constant evolution this Tesla factory is the future of the USA and the world that's the way I see it we are building the future here that's how proud I feel about this [Music]