08:49 22-02-2026

Tesla begins mass production of 4680 batteries with dry electrodes

Tesla has taken a key step in developing its proprietary 4680 battery cell. Mass production of cells with dry-coated anodes and cathodes has begun at the Austin factory. The 4680 format—a 46x80 mm cylinder—has reduced the number of cells in a pack and simplified assembly. Eliminating internal tabs has also lowered resistance and simplified the design. The Texas-built Model Y was the first to receive these cells, followed by a significant portion of production going to the energy-intensive Cybertruck.

The new process does not change the battery chemistry. These are still lithium-ion cells with liquid electrolyte. However, it radically simplifies manufacturing: instead of using a paste with solvents, Tesla presses the electrode material mixture dry. This eliminates long drying lines, reduces energy consumption, and cuts costs. Until now, the technology was only applied to the anode. Now it has been stabilized for the nickel cathode—the most complex part.

Simultaneously, Tesla is building its own supply chain. It produces cathodes in Texas and, starting in 2025, will recycle lithium in Robstown. This reduces dependence on external markets and lowers logistical risks amid trade restrictions.

Yet, a sudden increase in vehicle range should not be expected. The previously shown 272 Wh/kg in the Cybertruck resulted from changes to the cathode composition and cell structure, not the new manufacturing process. Dry electrodes theoretically allow for thicker layers and higher energy density, but Tesla has not announced any achievements in this direction yet.

The real impact lies in economics. If the company scales this new technology, the cost per kWh will drop. This opens possibilities for cheaper models or higher margins. Tesla's revolution is not under the hood, but on the factory floor itself.