Thoughts on what Tesla will announce on battery day in April & how Tesla’s future battery strategy will come together:
- Use cell supply from Panasonic/LG/CATL to bridge to ramp of in-house cell production (possibly towards ~90GWh contracted from these three suppliers).
- Announce that in-house cell production has just started (Apr-20) on a small scale (likely for Semi or Plaid Model S), with plans to ramp significantly in 2021 (potentially for all future new capacity from 2021).
- Announce a roadmap to reach 2TWh of annual in-house battery cell+module+pack production capacity by 2030. Enough for ~20 million annual EV sales and ~750GWH annual stationary battery storage sales.
Possible relatively short term technology breakthroughs:
- Tesla will apply agile development to its in-house cell manufacturing as it does everything else - so flexibility for rapid upgrades and iterations of the process to accelerate cost experience curves.
- Use Maxwell dry electrode tech to reduce manufacturing cost and footprint.
- Maxwell dry electrode tech leads to better physical properties, in particular allowing thicker cathodes (higher cathode % per cell) & possibly new chemistries.
- Move to use of single crystal cathodes - possibly helped by Maxwell process/other in-house R&D. This was a big part of the 1 million mile cells tested by Dahn.
- Use very carefully selected electrolyte additives following Dahn research.
- Highly automated manufacturing process to reduce staffing bottlenecks to production ramp.
- Tesla Hibar designs systems for electrolyte insertion during the cell manufacturing process.
- Combine all this with further in-house developed cell IP and possibly third party licensed tech. (Remember there are many steps in cell manufacturing and Maxwell/Hibar are only part of this)
- Reduce cathode kg per kWh to reduce raw material cost
- Next generation in-house module/pack lines for continued reduced cost & capex.
- Build a huge factory to build in-house cell/pack manufacturing equipment at scale (the machine that builds the machine that builds the machine) - significantly reducing capex per GWh capacity
Possible Longer term breakthroughs:
Note these are all just possibilities (based on acquisitions, press leaks, published scientific papers, patents & speculation):
- Integrated cell & pack design & manufacturing process to reduce footprint & cost.
- Dahn lithium metal anode allows for much thinner anode, higher energy density & longer electrode life (at the expense of shorter electrolyte life).
- Replaceable electrolyte design to extend lithium metal anode battery life. Develop Hibar machines for easy electrolyte replacement in service centres.
- Dahn research is used to eliminate cobalt from the cathode leaving just Nickel Aluminium or Nickel Manganese.
These various steps & incremental improvements may or may not be introduced once they have been proven ready for affordable mass manufacturing.
Some things I thing would help accelerate and de-risk Tesla’s battery cell ramp plans:
Tesla cannot trust & rely on third parties to deliver such critical components of its business plan, particularly when the metals market leaders do not believe in an EV transition as aggressive as Tesla is targeting.
- Buy Panasonic’s GF1 business for cell manufacturing employee experience (who can be used to train new employees on Tesla’s cell lines) and other cell IP.
- Buy/build Cathode powder manufacturing expertise (currently Panasonic mostly uses Sumitomo). Cathode powder is likely ~20% premium to its raw material constituents & the process can be key to cell properties.
- Buy Nickel Sulphate & lithium carbonate/hydroxide processor expertise - this will be a huge % of cell cost & Tesla’s plans require ~10x the current Nickel sulphate & Lithium market size.
- Buy other suppliers in the cell manufacturing chain
Speculation:
Will Tesla introduce their in-house better battery cells abruptly or gradually? By replacing all current cells or supplementing them? The consensus here seems to be gradually-by-supplementing. I tend to disagree. Consider the Osborne argument.
If Tesla announces dramatically better battery technology coming SOON, won't that hurt sales of cars with the inferior batteries? Even if only Plaid S/X and Semi get the new batteries first, won't a substantial number of 3/Y buyers assume they are coming to 3/Y and wait?
If I was a tech company with dramatically better tech in the pipeline, I would quietly test it, make damn-sure it is ready, sneak it into all my products, and THEN announce it. This is exactly what Tesla did with their first self-driving hardware.
All Tesla Cars Being Produced Now Have Full Self-Driving Hardware
Will Tesla do this again with their super-batteries?
Possibly supporting evidence:
1) The Maxwell, Hibar, and Jeff Dahn acquisitions occurred quite awhile ago. And presumably Tesla started testing the desired technology long before they paid for it.
2) Tesla has the ability to software-limit battery performance and unlock it later. Could cars start getting the new batteries in secret?
3) Tesla announced greater range for Model Y but not Model 3. Why one and not the other? Was it because Model Y can't be Osborned? (because it's not being delivered yet)
4) Tesla didn't promise profitability this quarter due to ramping up new products. Could those products include new batteries?
5) Tesla has proven ability to keep secrets (FSD hardware, Cybertruck design, etc.) and move faster than anybody expects.
6) Rumors of a major S/X refresh last year reportedly did hurt sales until Elon quashed the rumors. So Tesla is quite aware of the Osborne problem.
7) Battery Day is now promised for April, which presumably means after the Q1 Production/Delivery Report in early April but before the Earnings Report in late April. Isn't this the perfect time to wow the market and explain that Q1 earnings will be weak because of ramping costs, not weak sales?
8) Elon has bet the company on new technology before.
9) Anything else?
Possibly contradictory evidence:
1) To my knowledge, no one has reported new battery equipment or production. (But see #5 above.)
2) Maybe abrupt introduction is higher risk than gradual. (But see #8 above.)
3) Anything else?
Importance to investors:
Maybe not much. We already know TSLA has a megaton of positive catalysts coming soon: Shanghai ramp and expansion, Berlin construction, Model Y ramp, Solar Glass ramp, Semi launch, Full Self-Driving updates and revenue recognition, Fiat-Chrysler payments, tax allowance credits, S&P 500 inclusion, bond upgrades, and haloes from Crew Dragon and Starship and Starlink and Boring tunnels and Lord knows what else Elon delivers.
But a possible April announcement that all Tesla models have dramatically better batteries NOW (in April), not later, seems one more reason for TSLA longs to hang onto their heinies and their shares.
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