Tesla’s 4680 Model Y is making a return

Tesla has confirmed it has restarted production of battery packs for certain Model Y vehicles using its in-house 4680 battery cells. The restart comes after the company that had previously discontinued the Model Y variant following reports of poor real-world performance, including underwhelming range and slow, inefficient charging. The 4680 battery cell, first introduced at Tesla’s Battery Day in 2020, was promised to lower battery costs while improving energy density and manufacturing efficiency. The larger cylindrical format allows for fewer cells per pack, simplified wiring, and improved thermal performance compared to Tesla’s 2170 cells. Another benefit was the structural battery pack in which the cells were being placed, reducing weight and part count while improving rigidity, safety, and manufacturing efficiency. Tesla initially began producing Model Y vehicles with 4680 battery packs at Giga Texas, but later stopped selling this variant as it focused on improving yields and scaling the new manufacturing processes. Owners of these vehicles also reported poor charging performance, which was likely another reason production was paused and the variant discontinued. Since then, all Model Y vehicles have continued to rely on 2170 cells. However, that appears to be changing soon, as Tesla announced in its Q4 2025 shareholder deck that the Model Y will soon return with a 4680 battery pack. Tesla indicated it was doing this in part due to supply chain issues. “We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks,” Tesla said. The update was shared alongside new details on Tesla’s battery operations, including progress at its new lithium refining facility, which has now entered pilot production and is the first in North America to process spodumene into lithium hydroxide. Tesla says the facility uses a simpler, more cost-effective process with a smaller environmental footprint, while reducing reliance on overseas suppliers. This latest confirmation indicates Tesla has restarted limited production of battery packs using 4680 cells for Model Y, now supported by domestically produced dry electrodes and locally sourced anode and cathode materials. Tesla did not disclose which Model Y variants are set to receive the updated packs or the volume being produced, or a timeline for when we can expect to see these vehicles appear for sale. Hopefully when it does return, Tesla will have addressed the issues that plagued the initial batch of 4680 Model Y vehicles.