Tesla Fremont Expansions and Improvements

Tesla is expanding facilities in Fremont and increasing production. They adding 64,000 square feet to a 120,000 square foot tent structure and making it a permanent building. Land purchases in 2013 and 2016 added a total of 60 acres. The expansion of the tent area is relatively minor. However, merging the Model S/X production line and using space-saving Gigapresses should provide Tesla with 20-30% more space to increase Model Y production.

The Tesla factory was originally on a 370-acre (16,000,000 sq ft; 1,500,000 square meters) site and most activity concentrated in the 5,500,000-square-foot (510,000 square meters) main building that does the final assembly of vehicles. Tesla built a casting foundry in Lathrop in 2015 supporting the Fremont production and leased 1.3 million sq ft of warehouses in nearby Livermore in 2017.

In 2017, Tesla won approval to almost double the size of the facility with about 4.6 million new square feet of space.

The Gigapresses can save about 10% of the space in the factory. Many robots and production area is not needed to weld 170 parts together. This could mean 1 million square feet of space could be repurposed.

Merging the GA1 and GA2 Model S/X production lines might save another 15% of factory space.


• GA1/2 Model S/X (GA1&2 merged into a single line)
• GA3 Model 3
• GA4 Model 3/Y (tent)
• GA4.5 Model 3/Y (becoming permanent)
• GA5 Model 3/Y (indoors next to GA1&2)

In January 2021, Tesla indicated that Fremont had 600,000 cars per year capacity. Tesla’s Fremont factory can produce 500,000 Model 3/Model Y a year. Model S and X output can be 100,000 a year.

There is room for battery lines and production expansion at Fremont. In 2016, Elon Musk talked about producing 1 million cars per year from Fremont.

By the end of 2021, Fremont could produce up to 750,000 cars per year and have 10 GWh/year pilot battery production. A more conservative estimate is that Tesla Fremont will add 100,000 cars per year of capacity by the end of 2021 and another 100,000 cars per year of capacity by the end of 2022.

Shanghai has completed a Model Y factory and is ramping production this year. Tesla should have production capacity for 650,000 cars per year in Shanghai by the end of 2021 and 800,000 cars per year by the end of 2022 and 1 million cars per year by the end of 2023.

The Berlin and Texas factories are getting a lot of attention and could each add 500,000 cars per year of production by the end of 2022. However, there is constant expansion and upgrading at the Tesla Fremont and Shanghai factories.

SOURCES- Tesla, InsideEVs
Written By Brian Wang, Nextbigfuture.com (Brian owns shares of Tesla)

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