Tesla Semi battery redesign enhances winter performance

Tesla has implemented a redesigned battery structure for its Semi Long Range truck. At its core are the 4680-format cells also used in the Cybertruck, but the battery pack itself features a new architecture.

The company has moved away from a traditional flat layout to a vertical structure with densely packed cells. This design reduces the surface area exposed to the environment and helps retain heat more effectively, a crucial factor for operation in cold climates.

Range loss in winter is a significant challenge for electric vehicles. Under normal conditions, the drop can reach 20–40%, which increases operational costs and necessitates more frequent stops.

In Tesla's new design, the battery acts as a thermal buffer, keeping warmth contained. The system is further supported by a heat pump that redistributes energy from the motor, brakes, and ambient air to maintain an optimal operating temperature.

The battery pack is also integrated into the chassis's load-bearing structure, enhancing overall rigidity and simplifying assembly. This solution is already in use on production versions of the Semi, which began manufacturing in 2026. These technologies strengthen the business case for electric trucks, particularly in colder regions.