How Tesla Shed 400 Pounds From the Model X

Sometimes the most meaningful upgrades don’t come from flashy software releases but from trimming weight where it counts. In a recent discussion with Car and Driver, Lars Moravy, Tesla’s VP of Vehicle Engineering, explained how the team managed to remove almost 400 pounds from the Model X over the years. The work strengthened performance, improved range, and lowered energy consumption without changing the SUV’s core personality.

Moravy joked that his engineers earned a case of beer for every kilogram they removed. Judging by the final result, the engineering team enjoyed quite a few cold ones. He later posted on X, writing,

“Mass is everything, safety, efficiency, attributes, energy, consumption, cost. If you don’t care about mass you don’t care about your customer.” That attitude shaped every decision.

The changes didn’t come from one big redesign. They came from many quiet improvements that added up. Tesla started with the powertrain, switching the rear induction motor to a permanent magnet design and refining the half shafts. Those two updates alone cut about 100 pounds. The battery pack received a similar treatment. Tesla kept the same total capacity but used denser cells and a new vertical layout. By removing roughly 300 cells and tightening the structure, the pack dropped around 90 pounds.

Inside the cabin, Tesla trimmed weight through smarter components and new manufacturing methods. The airbags were integrated into the headliner fabric and the seating layout was reworked. These choices cut another 80 pounds while keeping the interior premium. Even the wiring got leaner. Engineers swapped copper for aluminum and optimized the high-voltage path, trimming roughly 44 pounds. A simplified cooling system added another 30-pound reduction.

The structure of the Model X evolved as well. Larger front and rear megacastings replaced several smaller pieces, going from eight key components to four. That update saved more than 20 pounds and boosted torsional stiffness by about 10 percent. More small wins followed. A lighter lithium-ion 12-volt battery cut 14 pounds. Updated suspension parts removed another 10. Thinner exterior fascias saved 10 more, and a redesigned refrigerant manifold shaved off 3.

For Tesla, these cuts matter. A lighter vehicle uses less energy to move, delivers better real-world range, and feels more confident on the road. Drivers feel these benefits in the way the Model X accelerates, brakes, and handles daily driving. Safety can improve as well when weight is managed throughout the structure.

Inside Tesla engineering, the phrase “mass begets mass” is a common reminder that every pound removed helps prevent more weight from creeping in later. Moravy closed the conversation with praise for his team, saying, “Hats off to the team that cut all that mass and made a better and less expensive car.”

The Model X weight drop is a clear example of how Tesla works behind the scenes. Big gains come from small, steady improvements that most owners will never notice directly, yet benefit from.

Source: DriveTesla