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Electric vehicle (EV) battery design continues to evolve at a rapid pace — and few automakers drive innovation like Tesla. In a recent teardown project at Munro & Associates, engineers took a first-ever deep dive into a 2020 Tesla Model X battery pack. The findings offer valuable insights for automotive engineers, EV enthusiasts, and investors keen to understand Tesla’s battery architecture, cost reduction strategies, and lean manufacturing trends.
As an engineering consulting firm specializing in competitive benchmarking, teardown analysis, and cost reduction, Munro & Associates regularly dismantles and studies EV battery packs from across the industry. This project included multiple Tesla packs — from Model 3s and Model Ys to a non-Plaid Model S and three Model X units. Here, we focus on one of the more intact Model X battery packs, providing a snapshot of its evolution and engineering choices.
Pack Overview and Architecture
The battery pack examined is a 100 kilowatt-hour (kWh) unit consisting of 16 modules built from 18650 cylindrical cells — a proven, high-density format in Tesla’s battery lineup. By contrast, the 75 kWh variant uses just 14 modules, achieved by physically de-contenting the front compartment rather than software limiting, which had been common in earlier Teslas. Interestingly, Tesla now appears to be reverting to a common pack approach with software-based range upgrades.
Physically, the Model X pack is larger than its Model Y counterpart, offering increased length and width. While newer Tesla packs — such as those in the Model 3 and Model Y — feature aluminum stampings and structural foam, the Model X design relies heavily on aluminum extrusions. This is a typical first-step approach, as extrusions allow for rapid iteration and lower tooling costs when refining initial designs.
The use of extrusions also correlates with production volume. The Model X and Model S are lower volume vehicles compared to the mass-market Model 3 and Y, making extrusions a more flexible choice for these platforms.
Pack Construction: Strengths and Differences
The Model X pack employs a stamped steel cover (not shown in the teardown but visible in supporting photos), topped with a plastic sealing sheet and sound deadening layer to mitigate noise and potential fastener corrosion. Notably, the lid plays a structural role: there are no discrete intra-pack fasteners anchoring the modules. Instead, modules are seated in place and clamped down when the lid is installed. This lean design simplifies assembly and reduces part count — hallmarks of Tesla’s cost-conscious engineering.
In comparison to other packs — such as Lucid’s, which require removal of fasteners and careful handling of bus bars — the Model X design eliminates risks associated with floating fasteners near high-voltage components. It also facilitates faster assembly, improving safety and reliability.
Pack Swap Legacy and Serviceability
One of the pack’s most distinctive features is its origin as a pack-swapping platform. Back in 2013, Tesla demonstrated automated battery swapping to address range anxiety, using packs designed for quick removal via Z-axis electrical and coolant connectors. While this approach has largely been abandoned in favor of supercharging infrastructure, the legacy architecture remains.
For service technicians, this translates into exceptional serviceability. The entire pack can be removed from underneath the vehicle without disturbing cabin trim, carpets, or seats — a sharp contrast to many modern EV designs. With experience, Munro engineers found they could unbolt and drop a Model X pack in just 10 to 15 minutes using a lift table — far quicker than with many competing vehicles, including some Lucid and Porsche models.
This efficiency improves long-term maintainability and reduces service labor costs — a tangible benefit to both Tesla owners and fleet operators.
High Voltage Architecture and Safety Features
At the rear of the pack, a compact contactor and high-voltage terminal subassembly manages power distribution. This design is more integrated and space-efficient than similar systems in the Model 3 and Y, showcasing Tesla’s ongoing refinement of electrical architecture.
An especially unique element is the mid-pack pyrotechnic fuse. While common in modern packs, this one features its own onboard lithium-ion battery power supply — a first among teardowns at Munro. This allows for independent actuation even when the high-voltage system is off. The design likely requires replacement if the internal cells degrade — an example of Tesla’s focus on modularity and fail-safe operation.
Thermal Management Evolution
Thermal management remains a critical factor in battery performance, longevity, and safety. The Model X pack illustrates Tesla’s evolving approach. In earlier versions, modules used free-floating thermal pads and extruded cooling ribbons. In this 2020 model, Tesla transitioned to micro-extrusions aligned with the cell edges, bonded with a silicone-based gap filler.
While this represents progress, the thermal contact area remains limited compared to newer designs like the Model Y 4680 structural pack or Model S Plaid, which achieve greater surface coverage and better heat transfer. Gaps between cooling channels and cells are still present in this Model X pack, indicating room for improvement — and offering a clear view of Tesla’s iterative engineering process.
Tesla Model X Battery Teardown Takeaways
This teardown reinforces several key insights about Tesla’s approach to battery design:
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Lean manufacturing: By using extrusions, multifunction fasteners, and lid-based clamping, Tesla minimizes part count and assembly complexity.
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Iterative improvement: Thermal management and cell architecture continue to evolve year over year, with each generation refining weaknesses in prior designs.
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Serviceability: The legacy pack swap architecture results in a battery pack that is far easier to remove and service than most competitors — a real-world benefit.
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Platform differentiation: Lower-volume vehicles like Model X retain older engineering choices (extrusions, 18650 cells), while high-volume models push into newer technologies (structural packs, 4680 cells).
For investors, the teardown provides additional context for understanding Tesla’s competitive position. The company’s ability to apply lessons from legacy platforms while rapidly iterating new designs remains unmatched in the EV industry.
For engineers, this Model X battery offers a window into how Tesla balances innovation, cost efficiency, and serviceability — all critical elements in the race to deliver better, more affordable EVs.
Discover More With Munro
To explore more in-depth teardown insights and battery architecture reviews, or for detailed reports on Tesla’s latest battery packs, visit Munro & Associates or subscribe to Munro Live.