4680 Battery Pack: What We Found Under the Foam!

Sandy and Cory give an update on the 4680 Battery Pack from our Austin-Built Tesla Model Y.

If you like the content you’re seeing, please consider visiting our website or subscribing to our Patreon group for exclusive content.










Music from YouTube Audio Library [Aka YAL]
Music provided by RFM:

#Tesla #4680 #GigaTexas


  1. This 'recycle to hi-grade ore' strategy would make sense if all those 4680 cells expired at about the same time. But, that has not been the case so far, due to heat and power management inconsistencies and cell quality issues. So, is the strategy to make these cells expire at about the same time? Can it be done? Is Tesla doing it? Is anybody doing it?

  2. Why can't you just appreciate the intelligence that went into engineering and building this, instead of tearing it apart? Tesla is constantly re-engineering things to get to this point. After working there, I can truly say that's the total mindset of the company. I can't wait to see what the next 5 years holds…
    My only complaint with ALL the EV's…why the hands free driving??? One little hiccup and everybody dies. Don't want to drive? TAKE THE BUS.

  3. So Tesla just made their batteries unfixable, sweet.
    With this setup you cant change bad cells, you have to change the entire battery costing 15-20k dollars a piece, compared to a couple of thousands for changing cells.
    Also recycling is now just to forget with that foam… Will be to costly to repurpose these batteries, or recycle them.
    The man hours needed is staggering, when one hear how much work was put in to just show these few pieces…
    Make this car age badly, as ALL EVs loose capacity over time, and a Tesla will never be worth changing a battery on. And when changing cells now out of the question…
    Sustainability right there…

  4. A non engineer here but I'm wondering if there is anything that could go bad that's embedded in that foam? How hard/expensive would it be to get to and fix if there is anything that can go wrong? Also, thinking long term, is it practical/possible to replace the batteries if an owner had/wanted to in the future. Or would the life of the batteries out live other critical parts of the car that would cause the car to be end of life first? Guess what I'm wondering is the car essential disposable once the batteries are done?

  5. Greetings from Chile, Mr. Monroe, to you and your team, I love your work and videos.
    The structural battery is a very good idea, the implementation is a disaster, it does not allow to repair or recycle properly, also the pink foam is combustible, which makes it unsafe. I think it can be improved in a way that is safer, more easily recyclable and repairable, using preformed and fire-retardant plastic foam structures.

  6. Right off the bat this sucks. One day soon somebody will need to replace one cell. And you can't do it with this.

  7. According to Troy one Cell has 98 Wh. Can you guys confirm the pack size of ~80 kWh? Thank you 🙏

  8. Great video! I look forward to further tear down. For recycling, this is the most brute force method. Yes you can recover materials but this process is not cost effective and reported to be quite inefficient. I would have expected Tesla to have a plan to recover the 4680 cells individually.

  9. would be great to see a video that goes deep on the recycle process described by Sandy starting at 8:25

  10. Great video. Do these battery pack grow in size when fully charged? Is this why there is so much foam used between cells and on top and bottom?

  11. Battery recycling as ore only really works if you are "close" to million tons in raw material (similar to mining/refining actually)
    This is easily achievable in the future, but close to impossible right now, because there are not enough large battery packs to recycle right now.
    Tesla can already recycle the faulty cells they produce (not packs though) with very high efficiency, it is not public how they do this.

  12. I have to disagree on a point with Sandy. The huge recycling facilities are able to do the hydrogen bath, but those cost A LOT to maintain and implement. I think most of the commenters are talking about reuse. There's no way to reuse those battery packs after a couple of cells fail. You can't remove the bad ones and replace with good ones. On a normal battery pack It's not an easy job, but with the popularization of EVs, there will be more and more reconditioning shops for battery packs.

  13. Dissolve the foam. Take samples to lab…I bet everything is designed to be recycled

  14. What you need is meth…it will give you the ability to take anything apart but you will not be able to put it back together….

  15. Little over-simplified on the recycling part. Yes, you can grind this down to separate things but it takes a huge amount of energy, an unusable sludge remains, and you end up with raw materials that would be much cheaper to source from the environment (i.e., the business case isn’t there). It would be much better environmentally and economically to allow for disassembly and the direct reuse of parts/materials and that does not seem feasible with their design.

  16. it appears that the Model Y 4680 pack has 67.5kWh useable and that suggests 75kWh total. If the cells are 26.5Ah as we have seen elsewhere this would mean a pack is 96S8P, however, there looks like a lot more cells in this pack than that – do you have a total cell count for the pack?

  17. I can't help but think defective/old battery packs like this are going to be pulled apart by wreckers, with the cells tested and sold individually for DIY battery packs for campervans or DIY home solar etc. And then after that they go to to the acid bath meltdown ideally.

  18. So where are these freezing baths and grinders you are talking about. Just what u said they don't have the equipment setup to recycle. 🤦

  19. We also got a leak from electrified that it has 828 cells. We already know from multiple sources (Troy teslike, limitless factor) that a single cell has 98wh capacity. That means the 4680 model y has a capacity of 98×828 = 81kwh not the predicted 68kwh from current predictions from charging curve. So I guess that at its full potential this should have a range of 322 miles (claimed, 19% increase than 270). Also these 4680 cells are not at their full potential(no silicon, dry method at cathode). Troy teslike leaked that in 2023 these cells would have a capacity of 108wh (355 miles same model, same number of cells) and in 2024 a capacity of 118wh(388 miles claimed). So for the same number of cells and same weight(4680 model y and 2170 have about same weight) we will get an increase of 44 %.

    ps all of this is my opinion. If you disagree with something reply to me

  20. What kind of crap is Elon Musk building?Ich hoffe die Deutschen bauen nicht so ein Mist nach.Bei einem Defekt der Akku Elektronik muss der komplette Akku getauscht werden.Einzelne Module können nicht getauscht werden.Der Kunde wird sich freuen wenn zum Beispiel das BMS nach der Garantie defekt ist und er den kompletten Akku kaufen muss.

  21. As a software engineer but still a tinkerer with hardware, I really appreciate bringing in the point of recycling such a highly-advanced and highly-integrated product. I think it's time governments worldwide spent a good amount of money on improving recycling technologies.

  22. I am disappoint Sandy didn't get the Ricky Bobby reference. I wake up every morning and I piss excellence!

  23. I'm pretty sure the foam will dissolve in acetone, it shouldn't hurt the top frame (acetal homopolymer?) though.

  24. At 8:28 Sandy mentions immersing the pack into liquid nitrogen. I believe the main purpose for that is to arrest any chemical reactions so the the cell ceases to produce any terminal voltage. Next comes mill grinding which pulverizes the can and the internal contents to such a fine degree that the next step of recycling can be undertaken. Anyone else have insight into those processes?

  25. What a waste. Hate this types of companies that do this. I wouldn’t have bought my tesla if I saw this before.

  26. How on earth would you service that module if it were to get sent back to the factory with all of that foam?

  27. So its genius engineering and (relatively) easy to recycle… But a battery pack (and probably the car due to the ‘gigacastings’) cannot be economically repaired, the batteries cannot be repurposed and there aren’t that many salvageable parts in the whole car; effectively the vehicle is a disposable item. Resale/trade-in values will be next to nothing and if there is a problem in the battery the car is a write-off. Great for Tesla, but how is it a good deal for the purchaser?

  28. What a lunacy and unscientific BS. How much Tesla is paying you Old Geezer? How are you incentivised?

  29. As far as recycling the batteries, The biggest will be reusing the batteries for home solar storage. battery life ratings are to the 80% capacity. That pack at 80% would be great for home use.