For almost a decade, because of its electric car and new batter technologies, Tesla is in a unique position in the industry. As the most vertically integrated company in the auto-making world, Tesla has the ability to attack any piece or component of its vehicles or the manufacturing process to make it better and more cost effective. This is what Tesla has done with the new, revolutionary tabless 4680 batteries it is going to be using in its future electric vehicles.

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Tesla announced a new tabless battery on its Battery Day event last year to critical acclaim. It was not just an academic exercise for Tesla as it was borne out of a specific need.
Like other battery makers, Tesla had been purchasing its battery cells from suppliers that use their own proprietary chemistry and structure. This was working well until Tesla looked into the future and discovered that its battery supply chain could cause a problem. As a result, Tesla set to work on the core components of batteries as it we know them and came out with the tabless 4680 battery. What is the difference between a tab battery and Tesla’s tabless battery? While the battery is a complex concept best left to the experts, it is possible to have a general idea of what Tesla has done here. The common cylindrical lithium-ion battery uses cells made of several layers or strips of chemical compounds to store energy. The layers are the cathode and anodes with a separator layer in between them. The cathode layer and anode layer then connect to the positive and negative terminals of the battery using small metallic components known as ‘tabs’. The problem with tabs is that they could be the downfall of the whole battery, despite performing a crucial function. They can affect the battery performance and reliability, if not done right. For instance, when the tabs are welded unto the electrodes, there could be resulting welding burrs that can pierce the layer between the cathode and anode layers, causing an internal short circuit. This has the potential of causing a fire. Also, the step of inserting the separating layer between the cathode and anode layers introduces a time consuming procedure during the battery manufacturing process. What Tesla managed to do is to eliminate the need for the connecting ‘tabs’, hence the name ‘tabless’ battery. Instead, the battery uses a conductive portion that runs along the electrode. Using this method, there less distance for the electron to travel before reaching the positive and negative terminals. This is a win for physics, as explained by Elon Musk, the CEO. So what is the big deal about Tesla’s tabless battery? The biggest deal is that Tesla has used a radically different approach in battery design. It is basically what Tesla is known for anyway, taking problems apart to be able to come up with the most fundamental solutions. With this first-principles approach, Tesla managed to change both the battery and the battery manufacturing process, making each of them better, ie both of them ended up being optimized. It involved acquiring a few battery focused companies but hey, Tesla pulled it off at the end of the day. Tesla improved the efficiency and capacity of its battery, reduced the costs of production and the time taken for production. With the tabless structure, as noted earlier, a time consuming step has been eliminated in the production of the battery. That is the step of inserting the tab itself inside the battery. This simply means more battery in less time. New battery partners of Tesla are betting that close to a century of experience making car batteries has prepared it to manufacture a difficult-to-produce next-generation battery championed by Tesla as the key to unlocking cheaper and more ubiquitous electric vehicles. As part of Tesla’s update call held with the release of quarterly financial results Monday, CEO Elon Musk delivered an update about the 4680-format cells which we will get into later on in Tesla models.

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