Tesla has quietly transformed the Model X over recent years, shedding a significant 400 pounds without compromising its core characteristics or performance. Lars Moravy, Tesla’s VP of Vehicle Engineering, revealed during an interview with Car and Driver that the weight reduction was achieved through meticulous engineering efforts rather than drastic redesigns.
The powertrain modifications were among the most impactful changes. By switching to a permanent magnet design for the rear induction motor and refining the half shafts, Tesla managed to cut approximately 100 pounds from the Model X’s total weight. This adjustment not only reduced mass but also enhanced performance by improving efficiency.
The battery pack underwent its own set of optimizations. Despite maintaining the same overall capacity, Tesla opted for denser cells and a new vertical layout that eliminated roughly 300 individual cells while tightening the structure. These changes led to an approximate weight reduction of 90 pounds, further contributing to the vehicle’s overall lightness.
Inside the cabin, engineers focused on reducing mass through smarter component selection and innovative manufacturing techniques. For instance, airbags were integrated into the headliner fabric, cutting down on bulk while preserving the premium feel of the interior. Additionally, a reworked seating layout helped trim another 80 pounds without sacrificing comfort or quality.
The wiring system was also optimized for weight reduction by swapping copper with aluminum and refining the high-voltage path. This change resulted in approximately 44 pounds being shed from the Model X’s total mass. A simplified cooling system added to these savings, trimming another 30 pounds while maintaining functionality.
Structural improvements were not overlooked either. Larger front and rear megacastings replaced several smaller pieces, reducing the number of key components from eight to four. This change saved more than 20 pounds and increased torsional stiffness by about 10 percent. Other minor adjustments included a lighter lithium-ion 12-volt battery (saving 14 pounds), updated suspension parts (reducing weight by 10 pounds), thinner exterior fascias (cutting another 10 pounds), and a redesigned refrigerant manifold (shaving off 3 pounds).
