Welcome back everyone, I'm Jordan Geesege and this is The Limiting Factor. In Tesla's Q3-2023 earnings call, Drew Baglino made a statement about the 4680 production ramp that contained a lot of new information. Today I'm going to break down what he said line by line, what the implications are for the 4680 ramp, and what the impact could be on Tesla's cost of goods sold.
In short, after 3 years of waiting, it appears 4680 cell production is finally poised to deliver on the exponential growth and cell cost reductions that were teased at Battery Day. Before we begin, a special thanks to my Patreon supporters, YouTube members and Twitter subscribers, as well as RebellionAir.com. They specialize in helping investors manage concentrated positions. RebellionAir can help with covered calls, risk management, and creating a money master plan from your financial first principles.
On screen is Drew's full, unedited statement from the earnings call. All I've done is chunked it down into seven smaller statements so that we can address each one individually.
The first statement was, quote, 4680 cell production in Texas increased 40% quarter over quarter. Congrats to the Texas team for producing their 20 millionth cell off of line one, end quote. This roughly aligns with my projections in the last quarterly earnings call video. In that video, I said that based on the progress Tesla was reporting, it appeared that each month Tesla was seeing about a 21% improvement in production rate. And if that continued, they should reach 20 million total cells produced in October. However, although that ended up being correct, it doesn't exactly align with Drew's new comments from the Q3 earnings call. Drew set a 40% quarter over quarter increase, whereas I showed a 67% increase. That means although I got the average growth rate correct, the shape of the growth curve is likely different than what I had guessed.
Drew's next comment was, quote, Texas is now our primary 4680 production facility end quote. This is something that's been coming for a while because as Tesla advised in the Q4 2022 earnings call, in Texas they had four lines and various stages of commissioning and install, which is about 100 gigawatt hours of capacity. That means Texas has more than 90% of Tesla's 4680 production capacity, making it their primary production facility. As for the other 10% in California, we'll talk more about that later in the video.
Drew's third comment was, quote, where heavily focused on quality scrap is down 40% quarter over quarter. With the increased volume and yield improvements, sell costs consistently improved month over month within the quarter. Although we have a lot more work to do to achieve our steady state goals, and that is our priority. End quote. A 40% quarter over quarter improvement to the scrap rate is exactly what was reported last quarter as well. So Tesla's making huge advances in efficiency on a quarterly basis. However, they still likely have a long way to go. As part of the course for new battery lines, that a lot of material ends up in the dumpster for the first year or two of the ramp. That's because, as I've said in the past, the components within battery cells are the thickness of a human hair, which makes them difficult to manipulate at high precision and speed. That means a lot of ways for defects to occur and a lot of scrap until things get dialed in.
So why is Tesla's current focus on quality or scrap rates and cost rather than sell volume? My guess is that there's a few factors involved. First, their current production rate is higher than what's needed to support the ramp of the Cybertruck. As this video from Joe Techmyer shows, there's very few Cybertrucks currently coming off the production line. Meanwhile, the 4680 lines are producing enough cells for about 500 to 1000 Cybertrucks per week. Although they are continuously increasing the production rate of the 4680 line at Texas, they currently have the breathing room to focus on quality because they're ahead of the Cybertruck ramp. The focus on quality will mean further reductions in scrap rate and therefore reductions in cell cost to help improve the profitability of the Cybertruck ramp.
Lastly, what are the steady state cost goals that Joe referred to? I can't speak to what their short term goals are, but later in the video we'll talk about their long term goals, when they might hit them and the implications.
Drew's next comment was, quote, the Cybertruck sell with 10% higher energy density than our Model Y sell started production on line two in Texas, end quote. The 10% energy density increase is old news from last quarter. And if you'd like to know more about that, check out my last quarterly update video. The comment that production started on line two in Texas is new information and is very useful for assessing the ramp of the 4680. It confirms that the 10 and 20 million cell milestones they hit in June and October were for the most part from just one line. That matters because it means they're getting all the new technologies they unveiled at Battery Day dialed in on the first line. And now that they're copying that line, the ramps of the subsequent lines will happen rapidly.
On that note, many people are interpreting that Drew's statement that the Cybertruck sell starting production on line two means that the first line wasn't running the Cybertruck sell. I took Drew's statement at face value and I don't believe he was implying that line one is running a separate version of the 4680. Let's take a look at Drew's next statement to explore that further.
Drew said, quote, this quarter we convert to building 100% Cybertruck sells to simplify and focus the factory as we ramp all four lines in phase one over the next three quarters. End quote. The interpretation many people are making of this statement is that line one is producing an older version of the cell and will be converted this quarter. However, I have a different view.
Let's start by taking a look at the history. First, when Drew says the Cybertruck sell, my view is that he's referring to the generation two cell that was shown at the Cybert rodeo 18 months ago at the 4680 production line in Texas as both a photo display shown here and a deconstructed cell shown here. As you can see, it appears the top is welded shut and there's a spiral pattern at the center of the lid. That's as opposed to the generation one cell that's shown in this freeze frame from battery day that has no spiral pattern at the top and is crimped. I was able to get a hold of one of those cells early last year from the Kato road facility in California, which I sent to UC San Diego for a tear down. It's also the cell that Sandy Monro found in the Model Y from Texas at a time when the 4680 factory at Texas hadn't started production yet. That is, we know the generation one cell was definitely produced at Kato Road and there's no evidence that generation one cells were produced in Texas at a volume and quality sufficient for vehicles.
Beyond the cells and packs that were torn down, there's also circumstantial evidence that Kato Road was the only location where the generation one cell was produced. In mid-September, Cleaner Watt reported that Tesla was shutting down 4680 production at the Kato Road facility for upgrades and within the same week we saw Tesla pull the Model Y from their order page that we know contained generation one 4680s. It reinforces the idea that Kato was the sole source for generation one cells that went into vehicles.
On the other hand, as I said earlier, there is evidence that Tesla intended to produce the generation two cells at Texas with a new cell can based on displays at the cell line at Giga, Texas. In light of that information, my view is that the 20 million cells produced online one in Texas all used the generation two architecture and that line one doesn't need to be converted because it's already producing that cell.
So when Drew says they're converting to building 100% Cybertruck cells this quarter to simplify and focus the Texas factory on ramping all four lines there, what did he mean? In my view, in the first part of the sentence where Drew says, convert to building 100% Cybertruck cells, he means across Tesla's 4680 manufacturing facilities in Texas and Kato Road. As he said in his last statement, which I'll cover in a moment, they're retooling the line at Kato Road for next generation cells. Then in the next part of the sentence when he says, simplifying and focusing the factory, my view is that he's talking about the entire factory at Texas, not just the small pocket of the building that builds the 4680 cells. If Giga, Texas had to use both generation one cells and packs and a generation two cells and packs in the same facility, it would add unnecessary complexity with no additional benefit. It would make more sense to use the generation two cells produced in Texas for all vehicles produced in Texas. That's not to mention the cost savings from moving the packs around the factory, rather than shipping the generation one cells 1700 miles from Kato Road in Fremont, California.
Not if I'm wrong, and line one in Texas does need to be converted from producing generation one to generation two cells. If that's the case, there's a chance the 5gWh run rate that was likely reached in October could plummet this quarter. That's because they would have to upgrade line one in Texas from a battery cell can that's crimped to a battery cell can that's laser welded. That sounds simple conceptually, but in reality, it would be a big undertaking. I can't see a scenario where it wouldn't mean shutting the line down, replacing the necessary equipment, and recalibrating all the machines for a different cell design with a different number of parts and slowly re-ramping production. If Tesla's lines were capable of rapidly shifting between cell designs, I would expect that their Kato Road line would be that adaptable as well.
However, that doesn't look like it's the case if it's going to require re-tooling for the next generation cells. With all that in mind, I'm left with the conclusion that it wouldn't make sense for Tesla to have spent the last year ramping the first 4680 line at Texas only to re-tool it now just as the Cybertruck is ramping. It makes more sense that they've now got line one running well, and they're now copying it to line two, rather than ramping both lines on a new cell design.
Drew's next comment was, quote, phase two of the Texas 4680 facility is currently under construction. The additional four lines incorporate further capital efficiencies over phase one, and our target is for them to start producing in late 2024. End quote. In other words, Tesla is expecting the four current lines at Texas, which have a total production capacity of 100 gigawatt hours to ramp quickly enough that they're already lining up the next set of production lines. I'll cover that further when we get to my updated projections.
With regards to the further capital efficiencies, my assumption is that what Drew is referring to here is the simplified manufacturing process and reduction in factory footprint that was teased at Investor Day. Although the slide says G.F.N.V. or Gigafactory Nevada, they're likely installing the same or similar equipment at Gigataxas for phase two.
On that note, how much 4680 production capacity is Tesla building outside of Texas? First, Tesla has 100 gigawatt hours planned for Nevada. I don't expect that production to come online until 2025 because the factory hasn't been built yet. As for Gigabrelin, we do know that Tesla originally planned to ramp 100 gigawatt hours there, but there's no indication from the last nine months that 4680 lines have been or are being commissioned there. That may be because it makes more sense to focus on U.S. production due to the massive tax incentives there. So for now, I'm going to count Berlin out for cell production ramps for the next year or two. That assumption could be wrong, but if Tesla provides updated guidance in an upcoming earnings call, I'll update the table and cover it in my quarterly video.
Shanghai is a different story. There's plenty of battery capacity being built in China, and the cell and pack prices are low there. So Tesla doesn't necessarily have to build 4680 production in China at any time in the near future and can focus their energy elsewhere. So overall, between Texas and Nevada, there's about 300 gigawatt hours of 4680 capacity planned in the next two to three years. And that doesn't include any additional capacity that Tesla is sure to use from third parties. To put that production capacity in perspective, Tesla will probably only use about 150 gigawatt hours of battery cells this year. So 300 gigawatt hours will give them several years of runway.
With all that in mind, I don't expect Tesla to have any cell constraints in the next two to three years when they choose to ramp products like the compact vehicle, Cybertruck and Semi. Moving along, Drew's final comment was, quote, lastly, in Kato, we're retooling to enable large-scale pilot runs of our next-generation cell designs. Kato's long-term goal is to be the launch pad for new cells, one generation ahead of our mass production facilities, enabling faster iteration and smoother rampups of new cell designs. End quote.
There's three major points here. First, the Generation 1 cell line in Kato Road will need downtime for retooling to produce next-generation cell designs. Second, what do they mean by large-scale? My guess is that the upgraded line will still have the roughly 10 gigawatt hours of capacity that Elon advised of in the Q4 2020 earnings call. It would be impressive if they could expand that beyond 10 gigawatt hours, but it wouldn't necessarily provide much additional benefit if they're just using the line for test runs.
Third, what are the implications of Kato Road becoming a launch pad for new cells? As a bit of background, in the past, Kato Road was a research and development facility rather than a production facility. The 10 gigawatt hour pilot line was built at Kato Road because that's where some of the earlier development took place for the 4680. But based on my interpretation of reporting from Cleaner Watt and from Tesla's earnings calls, it appears that the pilot line at Kato Road ran into unexpected issues that may have forced the final development of the 4680 production process to occur in Texas. So in the interim, Tesla leaned on the pilot line at Kato Road to mass-produce 4680 cells for use in the Model Y.
What Drew is saying here is that it will no longer be used for mass production and can go back to focusing on R&D. What kind of R&D? In my view, the main focus will be on chemistry improvements. So far, Tesla hasn't focused on improving the cell chemistry of mass-produced 4680s because the focus was on just getting 4680 production working. That's because even slight changes to cell chemistry can cause dramatic changes to things like the cohesion and adhesion of the active materials in the battery cell, which in turn can mean weeks to months of adjustments to the production process to consistently produce high-quality battery cells. Now that 4680 production is going smoothly in Texas, the 10-gWh pilot line at Kato Road can be used to work those kinks out of new chemistries on production-scale equipment before passing them along to Texas and other locations for actual mass production. That should allow relatively seamless production ramps for new chemistries after they've been tested on the equipment at Kato Road.
As for the impact of the chemistry changes, as I pointed out in my last video, they could easily push the energy density of the 4680 above 280Wh per kilogram and potentially above 290Wh per kilogram in the next few years.
Before we move on to projecting where the 4680 ramp will go from here, several people asked me how the ramp of the 4680 so far compares to Tesla's original production ramp plans. Let's take a look. First, at Battery Day, Tesla showed this slide, which showed 100gWh in 2022. But due to poor wording during the presentation and a lack of notes on the slide, at that time we didn't know whether they meant cells consumed from all sources or if the figures were just meant to be for in-house production. In retrospect, it's clear that Tesla was talking cells consumed from all sources. So although many people assumed this was projecting the 4680 ramp, that doesn't look like it was the case.
However, Tesla did give guidance in the Q2 2021 earnings call that there was around a 50% chance that they would hit 100gWh run rate by the end of 2022. That means their guesstimate from mid-2021 is looking like it'll be about 2.5 years off if they managed to hit 100gWh run rate in late 2024 or early 2025. Although Tesla was over-optimistic about the 4680 ramp and that was nail-biting and frustrating at times, it looks like they're on track now and it's quite an achievement.
Overall, even at this early stage in the 4680 ramp, they already have what's probably the most productive battery line in the world and it's using a dry battery electrode coating technology that wasn't expected to hit the market for at least another couple of years. If they can continue to ramp the first line at Texas and rapidly clone it, then we'll finally see the explosion of battery cell production that was expected in the last 2-3 years after battery day.
On that note, let's do some projections and guesswork on where things are going next. As I showed earlier, on screen is the original projection that I showed back in July that used a 21% improvement rate, which turned out to be relatively accurate. If the 21% improvement rate holds, Tesla will hit 30 million total cells produced in early December, 40 million in January, and then 50 million in February. Hopefully, Tesla lets us know if they hit those specific milestones so we can follow along, but I wouldn't be surprised if the next update is a doubling or 40 million cells just before the next earnings call. We'll talk about the projections for deeper into 2024 in a moment.
Before we get into that, is continuing to project the 21% improvement rate into next year reasonable. The bull argument would be that Tesla's now reaching the steep part of the S curve where output skyrockets, and that'll become pounded by the fact that Tesla is now starting to spool up subsequent production lines.
As for the bear arguments, I see three. First as Drew said in the earnings call, the team is currently focused on quality. It could slow the 21% improvement rate.
Second, there may come a time in the next year or two that the 4680 ramp progresses so quickly that material supply becomes a challenge. For example, what if the 4680 ramp is dependent on the cathode plant at Austin, or their lithium refinery at Corpus Christi, and those projects run into delays? I imagine Tesla has fallback plans, but it illustrates the point. The factories and mines that support the 4680 ramp are as important as the 4680 production lines themselves.
The third bear argument is that because the current 5gWh run rate from line 1 at Texas is only at 20% of its potential run rate, they may run into more issues that affect the shape of the production S curve. However, the counter argument to that would be that we know the first 4680 line is capable of at least roughly 5gWh per year at steady state. But the key word there is steady state. Tesla probably did burst production runs on that line to test its maximum output before deciding to spool up the second line. That would have given them some indications of how the line handled faster production rates and therefore given them insights into what the improvement runway looks like for the 4680 ramp.
Overall, in light of the bull and bear arguments, and given that there are so many other potential variables, my view is that the most pragmatic way to project the 4680 ramp is to look at past performance. With that in mind, I'll continue to use the 21% month over month improvement rate until we get new information or advice from Tesla.
Now that we have a projection in hand for the production ramp, let's layer in some of the other information from the earnings call. First, Drew said that the first four production lines would ramp over the next 3 quarters. Some people might argue that he meant that the first four lines would be fully ramped in 9 months. If that happened, it would be excellent news. But my view is that the intent of his wording was to set up the next sentence where he says that the next four production lines from phase 2 will start production at the end of 2024, which is 3 quarters from now.
Let's look at why that is using the projection that we looked at earlier. At a 21% improvement rate, phase 1 should hit a 74 gigawatt hour run rate by the end of 2024. At 74 gigawatt hours, phase 1 will be 74% ramped, and at that point, the production S curve will be starting to asymptote, meaning that the improvement rate will start to slow as phase 1 reaches its nameplate capacity. So if Tesla wants a continuous ramp over the next couple of years, then I expect phase 2 to start ramping before phase 1 starts losing steam. This is why I don't think Drew meant that phase 1 would be fully ramped in 9 months ahead of phase 2, which would effectively create a pause in production increases between the two phases. If that's correct, it leads me to believe that Tesla is also projecting roughly a 21% improvement rate, because they're planning on starting the ramp of phase 2 when phase 1 would be in the steepest part of the projected S curve. That's when phase 2 would need to start in order to create a continuous ramp.
The second piece of information to layer in from the earnings call is that Tesla expects to hit volume production of the Cybertruck in about 18 months. Even if Tesla was able to beat that timeline and fully ramp the Cybertruck by the end of next year, at an average pack size of 130kWh and 250,000 vehicles per year, the Cybertruck line would at most be using about 33 gigawatt hours of cells per year in December of 2024. That's as compared to the projected 74 gigawatt hour run rate of the 4680 lines in Texas.
In other words, even in a bullish scenario for the Cybertruck ramp, at the end of next year there could be around 40 gigawatt hours of spare run rate for 4680 cells in Texas. If that happens, what could Tesla do with those cells? First, the margins of Tesla's energy storage products are currently 24% and increasing, while the margins for the automotive business are around 18% and falling. From that perspective, it makes more sense to use the 4680 cells to drive further cost reductions in vehicles, because that's where margins are the weakest.
Second, the high energy density nickel-based battery cells that are being produced in Texas are better suited for vehicles than grid storage products. Although Tesla will likely manufacture LFP 4680 battery cells in the future with lower energy density and higher cycle life that could be used for storage products, I don't see that happening in the next 18 months.
That means the best use case for the 4680 cells outside of the Cybertruck and grid storage are for the Model 3 and or the Model Y. Why not the semi-upcoming compact vehicle, S and X, or powerwalls? The semi-compact vehicle haven't started their production ramps yet, and the SX and powerwalls don't have enough installed production capacity to absorb a 40 gigawatt hour run rate of cells by the end of next year.
That's as opposed to the Model Y and or the Model 3, where 40 gigawatt hours of cells would equate to roughly 500,000 vehicles per year. If Tesla delivers 1.8 million vehicles this year, they only have to grow production by 27% in the next year to absorb those additional gigawatt hours.
With all that said, although it's interesting to talk about product level choices, as an investor my main concern isn't so much about which product each cell will go into, which I'm sure Tesla will make the right decision about, but rather how quickly the 4680 lines scale and how much that will reduce production costs.
On that note, let's take a look at how much the 4680 cells could reduce the production cost of Tesla vehicles. We'll look at costs without Inflation Reduction Act tax credits and then with those tax credits. Currently the average price for battery cells is around $100 per kilowatt hour. That means at the pack level they're about $130 per kilowatt hour. Yes, Tesla might be getting a better deal, but we don't need to be exact here.
The main purpose is to sketch out a rough guide for the impact of the 4680 on vehicle cost. If the average battery pack of the Model 3 and Y are 75 kilowatt hours, each pack currently costs Tesla about $9,750. Tesla's current target for the 4680 is $70 at the cell level, which I estimate would make the pack cost about $90 per kilowatt hour. That would make the cost of a 75 kilowatt hour pack using 4680 cells $6,750.
$9,750 for the current pack cost minus $6,750 for the 4680 pack would mean a savings of $3,000 per vehicle. Bear in mind that Tesla's probably about 18 to 24 months away from hitting that pack cost because their $70 cost target is likely calculated based on a fully ramped production phase. Even when phase 1 is early in the ramp, perhaps early next year, I expect the in-house cells will already be cheaper than third party options.
Regardless, if there's one question I have for the next earnings call about the 4680 ramp, it would be when do they expect the 4680 packs to hit cost parity with the average third party options.
Moving along, we still need to factor in the Inflation Reduction Act tax credits. For each kilowatt hour of battery cells that Tesla produces in the US, they're eligible for $35 in tax credits, as well as $10 for the packs, for a total of $45 per kilowatt hour. $45 per kilowatt hour times 75 kilowatt hours is a savings of roughly $3,400.
If we add in the potential $3,000 of production cost savings, that's a total of $6,400. Currently, Tesla's average cost of goods sold for their vehicles is about $37,500. $37,500 minus $6,400 for production and tax credit savings would make the new cost of goods sold $31,100 per vehicle.
Or looking at it another way, Tesla's current average selling price across all makes and models globally is around $44,000. To keep things simple, let's assume that applies to the average price for vehicles in the US specifically as well. A $6,400 cost reduction might allow the average cost of Tesla vehicles sold in the US to drop to $37,600 if those vehicles used the $46,80 sell, or about $41,000 if half the vehicles used the $46,80 sell.
That would considerably improve the margins of those vehicles and or allow Tesla to drop the price by several thousand dollars. In summary, nearly three years after battery day, it looks like $46,80 sell production is ramping in earnest.
Tesla isn't out of the woods yet, but the trajectory looks excellent and the actions they're taking, like converting Kato back to R&D and starting on Phase 2 of construction at Texas, inspire a lot of confidence. All continue providing updates on a quarterly basis until they're no longer useful.
But I have a feeling things will be getting more interesting in the battery space over the next two years rather than less interesting as Tesla rolls out more products, launches more production lines, and makes improvements to their battery sell technology.
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