Sandy Munro and his team visited Tesla's styling studio to get an inside look at the new Model Y, interviewing Franz and Lars, key figures in the car's design and engineering. The studio, located in a converted airplane hangar with a rich history, serves as the birthplace of all Tesla products.
The discussion focuses on the design and engineering changes made to the Model Y, differentiating it further from the Model 3. Franz explains that the facelift allows the Model Y to mature and establish its own identity. A key feature is the front light bar, inspired by the Cybercab and Cybertruck, which acts as a daytime running light (DRL). The headlights are now positioned where the old fog lights were, creating a more modern and aerodynamic front end.
The rear of the car also sees significant changes, including a one-piece light bar that uses reflected light. The light doesn't directly shine from the LED but is reflected, creating a soft, diffused glow that highlights the Tesla badge. Lars explains the addition of a thermoplastic spoiler above the light bar. It allows for a sharper edge than aluminum, which is advantageous for design and aerodynamics, improving rear lift balance and enhancing ride comfort by softening the rear damping.
Munro brings up the issue of wind noise from side mirrors. Regulations require them, and Tesla has optimized them for aerodynamics by adding a ridge to manage airflow and reduce buffeting. They touch on the future when full self-driving will eliminate the need for mirrors, as the car will use cameras for visibility.
Lars then details the extensive work done to improve the Model Y's NVH (Noise, Vibration, and Harshness) characteristics. They tackled the source of the noise by optimizing the tires' tread patterns and stiffening the body, increasing torsional stiffness and improving local point mobility at suspension attachment points. The suspension kinematics have also been completely redesigned, reducing anti-lift at the rear for more mechanical compliance and slowing down the steering ratio at the front for a more progressive feel. Frequency selective damping has been added, which provides better ride comfort.
Munro inquired about steer-by-wire technology and why it wasn’t implemented. Franz explained that changing over to steer by wire would require a massive supply chain change, so they had to prioritize other things.
They discussed a new "frunk" (front trunk) with a drain, designed for storing beverages. The interior is all new, featuring ambient lighting, a redesigned center console with hidden storage, and the return of stalks, which had disappeared from some models. Munro emphasizes the comfort and ergonomics of the seats, finding them perfect for his back issues. The seats have slight stylistic changes, but the seat foam is the same.
In the second row, there are new features: power recline and motorized seat folding. Lars highlights a challenge he put to the engineers: the seats had to fold down quickly by the time he walked from the front seat to the cargo door. He also discusses a subtle relocation of the second-row seatbelts to the seat pillar, which prevents them from getting tangled when the seats are folded.
Franz addresses a question about casting versus sheet metal, clarifying that the front end is reverting to sheet metal for commonality across factories and to ensure interchangeability. The rear end remains cast but has been redesigned to be lighter and require less machining.
Lars explains that a new hydraulic by-wire braking system, where the brake pedal connects to a sensor which actuates an electric motor, gives consistent brake pedal feel regardless of regenerative braking levels, allowing them to capture more energy. The electric motor decouples the pads from the brake rotors. They also discussed an upgraded refrigerant cooling system and a "Super Manifold V2" heat exchange unit.
When discussing economic factors, Franz and Lars said Tesla just aims to make the best car for the value that they can. They focus on the safety of the cars, and Lars notes that they strive to make the engineering solutions become the safest cars out there, which exceed just checking boxes of required regulatory safety tests.
Munro concludes with a short driving impression of the new Model Y, praising its quietness, smooth handling, and comfortable seats.