Legacy Model Y has been the world best-selling vehicle and world safest vehicle for crash. When it came to time to redesign new Model Y, I was leading the rear body structures development through CAE analysis. Model Y, as the pioneer in the industry to adopt world first gaga-casting technology combining more than 70 parts from rear under body (RUB) into one single piece of giant casting, are produced more than 1 million per year. Redesigning the new generation of RUB casting has great significance to both product and company.
Vehicle body (body-in-white) of new Model Y (Picture from Tesla official website)
Through CAE analysis with FEA, the giga-casting of new Model Y was completely redesigned to achieve maximum performance-cost efficiency. The same high standard of crash safety is achieved while reducing redundant material, structures and cost. Beside giga-casting, a new rear end structure system including rear bumper assembly was also re-designed and rolled out to improve overall structural crashworthiness.
The new Model Y was launched worldwide in January 2025.
Zheng Li 
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