Even before reports like this were coming out, I knew that structural battery packs and body castings were a bad idea. At one time I considered getting a Model Y, but no more, I'll stick with my '18 Model 3.
And it doesn't take a genius to figure out why. Body castings don't flex, they CRACK, and the cracks can go a long way. Even welding them up might not be good enough.
And structural batteries? Come on now. Batteries have enough problems with providing power. They don't need to be flexed and stressed as a body member on top of that. I've read that this battery can still be changed but it is a much bigger job.
Now I'm sure this new "technology" is all well and good for Tesla, get the vehicle made as fast and cheaply as possible, and sell it for big profits. But when repairs from a wreck are needed, they are taking the Apple route of "just buy a new car / phone / tablet / laptop".
Modular is better. Unbolt a battery pack and swap another one in. Sheet metal can be easier than castings that involve so much of the car that changing one is a massive job. Instead of one huge casting that is the whole rear half of the vehicle, maybe 4-6 castings bolted together that can be changed more easily, as a compromise.
I need to find a way to get in touch with Tesla top engineers and hold periodic video or in person meetings with them, to review their plans and go over UI / display improvements. I'm not saying I know everything better than them, but I do have useful input to share.
