Tesla details battery pack design for safety, durability, and longevity

Tesla published a technical article explaining how it designs its battery packs focusing on safety, durability, and longevity. Their approach covers cell chemistry and manufacturing through pack architecture and software monitoring in use. It highlights passive propagation resistance (PPR), which thermally isolates and structurally separates cells to prevent failure spread like thermal runaway. Tesla conducts PPR tests under extreme conditions beyond regulatory requirements. The company claims over 265 billion miles driven through 2025 without spontaneous battery fire in Model 3, Model Y, Cybe

• Tesla has driven over 265 billion miles without spontaneous battery fires
• Every cell undergoes 100% X-ray inspection and some receive CT scans

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