Moving from 40 kWh to 60 kWh on the Model S, customers have to pay an additional $10,000 for 20 kWh or $500 per kWh at retail. Jumping from 60 kWh to 85 kWh, customers again pay an additional $10,000 for 25 kWh or $400 per kWh HOWEVER the range jumps up by the same 70 miles (160 to 230 to 300) so it's not clear if that extra 5 kWh is illusory.
Mystery of the Missing 5 kWh
Tesla has stated that their gross margins are 25% so Tesla's cost should be about $450 x (1-.25) = $337.50 plus or minus $37.50. Elon reiterated in an article today he sees battery costs declining 7-9% per year so in 3 years that's a 20-25% reduction. So battery costs in 2015 would be $225 - $300 per kWh, $300 - $400 per kWh to the retail consumer.
I think that Panasonic should be long term greedy here. If Tesla can be successful and sell a lot of cars then two things will happen that benefit Panasonic greatly (1) Tesla will stay in business, continue to sell more and more cars and continue to buy millions of Panasonic batteries and (2) other car makers will switch to the Panasonic / Tesla technology and buy millions of batteries. This could be a tremendous growth area for Panasonic IF they bring the prices down that they charge Tesla as fast as possible, thereby reducing the EV premium and making the Model S, X and BlueStar more successful.
For the above reason I expect that in 2015 Panasonic will offer the 4.0 Ah batteries at prices only slightly higher than today's 3.1 Ah. Therefore I expect the 3.1 Ah batteries to be 20-25% cheaper than they are today. That will allow Tesla to lower prices on the Model S substantially ($4,000, $6,000 and $8,500 off each model respectively) or increase range by 33% (215, 300, 400 miles respectively) or add a lot more luxury features or most likely some combination of all 3.
It will also enable a Bluestar model for $30,000 - $35,000 with a range of 100-150 miles with the smallest battery pack.
I am hopeful that Panasonic makes it possible since battery cost will be the critical driver of EV adoption.