How Tesla created the electric car and a network of Tesla charging stations to support them

Tesla’s latest global expansion involves it’s new facilities in China and Germany to compliment it’s flagship Fremont factory in California. We look closer at how Tesla builds an electric car and innovations which made it succeed.

In 2020 the Freemont Tesla Factory can produce a total output of 590,000 with the projected volume scheduled to increase to 2 million with the launch of the new giga factories. So how was this all possible?

– Model S/X (capacity of up to 90,000 annually),

– Model 3/Y (capacity of up to 500,000 annually

How Tesla built the world’s most advance automotive plant.

Across 370 acres of land Tesla’s sprawling mini city consists of 5.3 million square feet of manufacturing and office space with the factory projected to double to almost 10 million square feet. Tesla’s complex employs over 10,000 automotive workers, however it started life as a GM and Toyota plant through the 60’s up until 2010. To modernise and improve the space natural light and painted floors created a clean work environment. The auto plant also has it’s own in-house shopping and medical facilities to ensure it’s workers are cared for.


Elon’s vision was always top produce a mass market electric car. He wanted to offer value, range performance without compromising design or function. With 6.5 million dollars and a small Silicon Valley warehouse a revolution was born. Using a Lotus Elise platform, they were able to develop the premium EV sports car. The initial intent was to just simply replace the engine with a battery and motor. However they quickly realised that there was a lot of engineering required from a battery cooling prospective & the associated knock on effects. 2 years behind schedule the roadster was born in 2008 selling 2,450 in it’s 4 year run. The roadsters where powered by a home tesla charger installation

Utilising Experienced Auto Engineers for it’s Model S

With the design of the Model S, Tesla hired automotive engineering experience from around the globe. But they didn’t stop there, they also focused on electrical engineers and software experts. Why just build a car when you can build a smart car. Finally Tesla stationed its design team within the manufacturing facilities improve efficiencies and innovation.

Tesla Employees in 2011 .

With the lessons learned from the roadster, the Model S would be it’s platform to disrupt and revolutionise the market.

Tesla learn it needed to abandoned standard vehicle layouts, with the battery pack positioned on the floor to take advantage of the improvements in space and balance. They positioned electric motors around the battery packs. By removing moving parts and an aluminium frame the vehicle began taking shape. It was faster, lighter and went further than any other EV in the world. They also provided a high powered Tesla charger to have rapid charging speeds.

Designing a Safe Electric Car

The 4 components that are essential in Tesla’s manufacturing are the power electronics module, high density batteries, powerful electric motor and the advanced software core (Tesla Motors, 2011). Tesla understood that battery technology was vital and therefore allowed ample space and flexibility to allow future innovation to be integrated into its core components. Tesla is #1 due to the sum of all parts. Tesla architecture allows the platform to expand across it future ranges which allowed it to produce the everyday Model 3 and Model Y

Tesla charging stations

Elons message was simple. They want ted to make driving an electric car as easy as owning an electric car. Therefore the investment was made to have upgraded on board charging capabilities and speeds. This was also complimented with a global network of Tesla Destination Chargers and DC Charging stations.

Tesla’s mission to continuously innovate led by CEO Elon Musk and its unique sexy branding allowed itself to market across generations of car buyers, producing a mass of loyal buyers and admirers. The automotive industry is now also evolving through the use of software and ride sharing with the prospects of automation. Tesla’s strategy is clearly geared towards tomorrow’s technology.

Sam Korkees is the directors of EVSE Australia, the nations leading supplier of electric vehicle charging stations, charging cables and all EV accessories. To know more about Tesla chargers and installation visit

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