Tesla is ushering in a new era of automotive manufacturing with its upcoming fully autonomous robotaxi, the Cybercab, which will be produced using the company’s proprietary hypercasting technology.
Hypercasting employs ultra-large die-casting machines to form an entire vehicle body in a single mold. According to Tesla, the process significantly boosts production speed and reduces manufacturing costs.
On April 22, Joe Tegtmeyer, a technology commentator who closely tracks developments at Tesla’s Giga Texas facility, shared images on X (formerly Twitter) showing what appeared to be early versions of the Cybercab’s body structure. The photos revealed several large castings that looked distinctly different from those used in the Model Y and Cybertruck, suggesting they could belong to a Cybercab prototype.
Tegtmeyer reported that the castings were made using Tesla’s giga casting process, particularly its advanced hypercasting method. The system involves a gigapress capable of applying 6,000 to 9,000 tons of pressure to mold a special aluminum alloy into a single large vehicle component.
Unlike conventional manufacturing methods that involve welding and assembling multiple parts, hypercasting simplifies the process. Tesla says it not only improves efficiency and reduces production costs but also enhances performance by lowering the vehicle’s weight—potentially increasing its driving range.
The Cybercab is being designed as a two-door, fully autonomous electric vehicle with no steering wheel or pedals. It will rely entirely on Tesla’s Full Self-Driving (FSD) software. The vehicle will feature Falcon Wing doors, reminiscent of the Model X, and a minimalist exterior with no visible Tesla logo. The company expects to price it under $30,000.
Tesla highlights the Cybercab production line as a major leap in manufacturing efficiency. The company estimates that one Cybercab could roll off the assembly line every five seconds—a substantial improvement over the Model Y’s 35-second production cycle.
Lars Moravy, Tesla’s Vice President of Engineering, said the company plans to begin producing Cybercab prototypes this summer, with mass production targeted for 2026.
CEO Elon Musk has emphasized that the Cybercab’s production line—and the factory itself—should be viewed as products in their own right. “Tesla factories—especially the next-gen Cybercab line—are the true product,” Musk wrote on X earlier this month. “The real focus should be on autonomy and Optimus,” he added, referring to Tesla’s humanoid robot project.
