Tesla slashes costs in HW4 computer with major hardware changes

Tesla has started making big changes to its HW4 computers to save money. A well-known Tesla observer, Green, shared details after taking apart the new hardware. Tesla removed many parts that are not seen as essential. This helps lower the price to make cars, especially ahead of new, affordable models.

Connector and battery removal

Tesla has taken out all connectors it does not see as necessary from the latest HW4 units. It also got rid of the small batteries (CR1220 lithium) that keep the real-time clock running when the car is off. That means after a full loss of power, the car could forget the date and time until it connects to power again. These small batteries are cheap, but cutting them from all cars saves a lot over time.

Changes to wiring harness

Tesla now uses the car’s metal frame to ground electrical systems instead of running separate thick copper ground wires. Traditional car design uses extra ground wires to protect against problems, but Tesla is relying fully on the chassis for this task. Over the last few years, Tesla has also slashed the total length of wiring in its cars. The Model S had about 3 kilometers, the Model 3 cut it to 1.5, and the next Model Y redesign aims at just 100 meters.

HW4 specification reductions

HW4 computers in Model Y use less memory and storage. They only get 8GB RAM and 128GB storage. The previous system (HW3) used 16GB RAM and 256GB storage. That means these cars cannot run Steam games, which need more memory.

The company dropped the discrete GPU and switched to cheaper memory without error correction. Premium audio hardware is gone too. Some camera connectors are not installed, which removes support for extras like front bumper cameras.

Tesla’s cost-cut plan is not the same in every car. The Model S and Model X keep HW4 setups. Model 3 and Model Y see more cuts and lower hardware. For example, the Model Y HW4 computer does not have some pieces, like high-definition radar or top audio systems, that show up in premium models. Not all camera ports are used, which might leave room for upgrades down the line.

Shift to easier manufacturing

Tesla is changing how it builds cars beyond just part cuts. The company wants more robots to put together new “modular” wiring. Instead of round wires, Tesla is using flat, rigid ones that work better with automation and cost less to put together. Tesla thinks this will speed up assembly and keep needed features.

Tesla is also reworking how cars come together in the factory. Instead of building cars step by step, it plans to put big sections together at once to save space and money. Tesla says this could shrink the whole manufacturing setup by over 40%.

Tesla has said its biggest goal is to cut vehicle costs by half to sell a $25,000 electric car. All hardware and process changes are part of this plan.

Trade-Offs for Owners

Cutting parts helps Tesla’s bottom line, but some drivers may lose features. Without the backup clock battery, cars could reset the time after losing power. Smaller memory means less room for fancy software and no Steam gaming. Relying on the chassis for grounding breaks from common auto rules, but Tesla says its testing backs up the method.

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