This is why I think cells don't necessarily need to be tab-less to be in a structural pack:-
Rivian says its battery pack has the highest volumetric energy density in the world, thanks to its cooling strategy - Charged EVs
My other thought is that metals conduct heat fairly efficiently, the contact point for cooling might not matter. Within the pack they want to prevent heat transfer between cells as far as possible, maybe air is sufficient insulation provide only a minimal area of each cell is in contact with adjacent cells.
I also think tab-less 18650 and 2170 will not be a big deal, provided the technology is licensed from Tesla.
For existing lines there are 2 options:-
- Covert existing 18650 / 2170 lines to tab-less.
- Covert existing 18650 / 2170 lines to tab-less 4680.
I don't know which of these options requires more time / money.
My best guess is regular Model S/X might have a structural 18650 pack, and Plaid Models might have a structural 4680 pack.
In terms of the immediate Model S/X refresh, we determined yesterday that swapping molds to produce front/rear castings for Model S/X with a structural pack might be difficult.
So one possibility is that Model S/X are built with a 1 or 2 piece rear casting only as per Model Y.
In that case, if an end-cooled 18650 pack was built, it would not initially be used as a structural pack.
Plaid Model S requires new casting machines, and then all Model S/X go could to structural packs at that time. The downside there is that is another significant production change