> On Mar 1, 2016, at 1:46 PM, EVDL Administrator via EV <[email protected]> 
> wrote:
> 
> I'm hardly an expert on these matters, but over 7000 cells in a battery? 
> Good grief. With the stupefying amount of labor that has to go into 
> assembling such batteries, I don't see how Tesla (or anyone) can ever build 
> an EV for the masses
> 
I have not been inside the Tesla factory (but I do drive past it every day), 
but suspect the construction of battery packs is almost fully automated. 
Machines handle the individual cells and spot weld them into modules (I think 
Tesla calls these bricks). Machines nay also automate the attachment of the 
monitoring and protection electronics.  With that much automation, extremely 
high reliability can be achieved.

As for making up costs in other places, note that the battery pack is a 
structural component of the vehicle. An electric motor is considerably simpler 
and less expensive than an ICE.   Although given the special materials in the 
Tesla motor, that might not be the case. AC Propulsion wanted $25,000 for it in 
single quantities. There is no exhaust system with catalytic converter. 

Ed
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