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Tesla says Model S crash test score is best NHTSA has ever recorded

We found out a couple of weeks ago that the Tesla Model S aced the crash tests administered by the National Highway Traffic Safety Administration. What we didn't know until Tesla filled in some of the details is that the Model S scored more than five stars on the way to recording the best result of any car the NHTSA has ever tested. While NHTSA's highest public rating is five stars, the Vehicle Safety Number it gives to manufacturers can go higher, and Tesla says the Model S scored a 5.4. That's a better result than has ever been achieved in NHTSA testing of a passenger car, SUV or minivan.
Tesla's press release says that after its internal tests showed that it would score five stars on government's crash tests, it addressed any other weak points it found on the vehicle to ensure it would get perfect marks "no matter how the test equipment was configured." It was already going to do well in the frontal test, as the lack of an engine allows much more leeway in creating an occupant-saving crumple zone. And the rollover test was aided by the battery pack being located in the floor. The low center of gravity meant that the Model S couldn't be rolled over "via the normal methods and special means were needed to induce the car to roll."
Nested aluminum extrusions along the hatchback's flanks took care of the side pole intrusion test, the Model S not only scoring five stars but, according to Tesla, leaving nearly nine times more "driver residual space" post-impact than the five-star rated Volvo S60. And when the roof of the Model S was tested for crush resistance, the testing machine broke just after it crossed the four-G mark - the Model S, on the other hand, didn't.

Tesla Gigafactory will be capable of supplying packs for 500,000 EVs a year

We made our gigafactory predictions the other day and, it turns out, we were pretty much on target. Today, Tesla Motors released the first official details on its upcoming massive battery plant and we see sun and wind power feeding energy into a plant that will employ around 6,500 people and make enough packs for around a half-million Tesla EVs a year. You read that right. Tesla is getting ready to produce 500,000 EVs a year, and that's already in 2020. Tesla hopes to start selling a lower-cost EV, the Model E, in about three years. The finalists for where the Gigafactory will be built include the Southwestern states of Nevada, Arizona, New Mexico and Texas (our money is on Nevada). We were a little low on the estimated battery output. Instead of being able to make 30 Gigawatt-hours of batteries per year, Tesla is saying that it will have enough capacity to produce 35 GWh of cells and 50 GWh of packs a year. We think that's for both EVs and stationary applications and have reached out to Tesla for confirmation on this point. You can see the details for yourself here and in our gallery below. Through 2020, Tesla will directly invest around $2 billion in the plant and its partners will pony up another $2-3 billion for a total cost of $4-5 billion. That's a lot of cash, but Tesla says that it will make buying an EV much, much cheaper. The company is saying that, once the plant is up and running for the first year, the per-kWh cost of a Tesla battery pack will be lowered by "more than 30 percent." Maybe that Model E isn't such a pipe dream after all. Also today, Tesla announced a new convertible notes offering worth $1.6 billion. Details are available in the press release below. Tesla Announces $1.6 Billion Convertible Notes Offering Wednesday, February 26, 2014 PALO ALTO, Calif., February 26, 2014 – Tesla announced today an offering of $1.6 billion aggregate principal amount of convertible senior notes in an underwritten registered public offering. Of the total offering, Tesla will offer $800 million aggregate principal amount of convertible senior notes due 2019 and $800 million aggregate principal amount of convertible senior notes due 2021.

Tesla could make 800 Model S EVs a week by late 2014

Tesla continues to impress, with high demand pushing the small, California-based company well beyond its initial projections of 400 Model S EVs per week. According to Tesla CEO Elon Musk, "We're above 400 a week at the current manpower, and not trivially above it." If things continue at the current pace, Tesla's Fremont, California factory, former home of the General Motors/Toyota NUMMI facility, will be pumping out 800 cars per week by late 2014.
That number will eventually come to include the Model X SUV and a smaller, more affordable alternative to the Model S. There's even chatter of a compact SUV, according to a story from Bloomberg.
Even if Tesla produces 800 cars per week for an entire year, the company hasn't even approached the maximum capacity of its Fremont factory. The NUMMI facility was producing 500,000 units per year during its glory days. And while that number is still far off for Tesla, Musk claims it'll happen eventually. "We going to have every kind of car you could possibly imagine. If it moves, we'll make it."