Tesla 4680 Batteries: Dry Electrode Finally Mastered

I still remember Battery Day 2020, when Elon Musk promised us a revolution with 4680 batteries and their dry electrode process. Six years later, on February 2, 2026, Tesla finally confirmed in its Q4 2025 report: the company now produces 4680 cells with anode AND cathode manufactured by dry electrode. A technical feat that Elon Musk himself describes as “incredibly difficult” on X.

This announcement marks a major turning point for Tesla’s technological independence. Let’s decipher together this breakthrough that truly changes the game in the electric battery industry.

The official announcement: Tesla finally masters the complete dry electrode process

In its Q4 2025 shareholder letter, Tesla confirms in black and white the complete mastery of the dry electrode process for its 4680 batteries. Concretely, what does that mean? Traditionally, electrode manufacturing requires the use of liquid solvents to apply active materials. The dry process eliminates this step, making production simpler, less energy-intensive, and more environmentally friendly.

Tesla had already succeeded in applying this technology to the anode, but it was the cathode that represented the true Holy Grail. Why? The chemical complexity of the cathode is infinitely greater, with materials much more delicate to handle without solvent.

On X, Elon Musk reacted to the announcement by highlighting the extraordinary difficulty of this achievement. Bonne Eggleston, Vice President of the 4680 program, also tweeted: “This is just the beginning”. A statement that suggests further innovations to come in this area.

Looking back at 6 years of development: why did this “breakthrough” take so long?

The promises of Battery Day 2020

During Battery Day 2020, Tesla announced ambitious goals: a 56% reduction in cost per kWh and a 54% increase in driving range thanks to 4680 batteries. The initial timeline suggested rapid production. Six years later, we are finally there.

This discrepancy between promise and reality has drawn legitimate criticism within the Tesla community. But this timeline must be put back into its technical context.

The technical challenges encountered

Musk acknowledged it: the dry cathode represented a challenge of unprecedented complexity. The large-scale industrialization of an experimental laboratory process requires overcoming hundreds of technical obstacles. Every parameter – temperature, pressure, application speed – must be perfectly controlled to guarantee quality and reproducibility.

Tesla didn’t just accumulate delays: the company solved a problem that no one else in the industry had managed to overcome. This contextualization is essential to appreciate the scale of the technical achievement.

The concrete advantages of the dry electrode process for Tesla and its customers

Beyond the technological feat, what concrete benefits does this innovation bring? The reduction in production costs is at the top of the list. By eliminating solvents and associated drying steps, Tesla significantly reduces its energy and operational expenses.

The industrial simplification is another major asset:

• Elimination of long solvent drying steps
• Reduction of the production plants’ footprint
• Increased scalability for mass production
• Decrease in overall energy consumption

The environmental impact also deserves to be highlighted: fewer chemicals used, less energy consumed, less waste generated. For us, end customers, this will potentially translate into lower prices in the medium term and improved performance on future vehicles equipped with these batteries.

Production started in Austin: the first Model Ys with “full dry electrode” 4680 batteries

Tesla has confirmed the start of production of these new cells at Gigafactory Texas. Model Ys produced in Austin will be the first to benefit from this cutting-edge technology.

This decision is part of a broader anti-tariff strategy. By diversifying its battery supply and producing locally in the United States, Tesla protects itself against trade tensions, particularly with China. This geopolitical dimension aligns with the challenges of diversifying battery supply that I have already mentioned.

Several questions remain unanswered: what is the current production volume? What percentage of Model Ys will be affected? When will this technology arrive in the European and Asian markets? My analysis: this technological independence represents a major strategic advantage for Tesla against competition and geopolitical uncertainties.

What this concretely changes for us, Tesla owners

Let’s be honest: in the short term, this announcement will have little impact on current owners. Our vehicles will continue to function exactly as before, and it is important to continue to optimize their battery performance with embedded technologies.

In the medium term, however, the prospects become interesting:

• Potential decrease in prices of new Model Ys due to production savings
• Improved driving range if energy density gains are confirmed
• Better vehicle availability with accelerated production

In the long term, the impact will likely be more significant: democratization of this technology across the entire Tesla range, reduction in battery replacement costs, and above all, strengthening Tesla’s competitive position against other manufacturers who are still struggling to master these advanced processes.

My personal conclusion remains cautious: this announcement is undeniably a major breakthrough, but I’m waiting to see concrete production figures, durability tests, and real-world road performance before declaring victory. To further understand the electrode drying process, I recommend consulting the official technical data that details these complex processes.