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Tesla Model S

Battery-electric full-size car

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Tesla Model S 90 D
Peteratkins · CC BY-SA 4.0

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Tesla started developing the Model S around 2007 under the codename WhiteStar, with Henrik Fisker appointed as lead designer for the project. After a dispute with Elon Musk, Tesla's CEO, Fisker was replaced by Franz von Holzhausen who, by 2008, had designed the production Model S's exterior. Tesla unveiled a prototype of the vehicle in March 2009 in Hawthorne, California. In 2010, Tesla acquired a facility in Fremont, California, to produce the Model S, which was previously owned by General Motors and Toyota. Series manufacture of the car officially began at the Tesla Fremont Factory in June 2012. Tesla carried out the final assembly for European markets at its facilities in Tilburg, Netherlands, between 2013 and 2021.

Constructed mostly of aluminum, the Model S shares 30 percent of its components with the Model X—a crossover SUV that was introduced in 2015. The Model S underwent several updates during its production, the most prominent ones occurring in 2016 and 2021. These updates usually included modifications to the motor, such as changes to power or torque, revised exterior elements, and refreshed interior features. One such change included the 2015 introduction of Tesla Autopilot—a partial vehicle automation advanced driver-assistance system. The 2021 update led to the introduction of the high-performance, three-motor Plaid. Tesla ended production of the car in May 2026.

In 2015, the Model S was the world's best-selling plug-in electric vehicle. In 2012, it was included on Time's list of the Best Inventions of the Year, and the magazine later included it on its list of the 10 Best Gadgets of the 2010s in 2019. Car and Driver included it one its list of the best cars of the year in 2015 and 2016. In 2014, The Daily Telegraph described the Model S as a "car that changed the world". Road & Track argued that, with the introduction of the Plaid and features such as the yoke steering wheel, Tesla managed to turn the Model S into "perhaps one of the worst [cars in the world]".

Development

In January 2007, the American automaker Tesla Motors opened a facility in Rochester Hills, Michigan, employing sixty people to work on new projects, including a four-door sedan. Beginning development under the codename WhiteStar, Tesla planned for the car to have two powertrain options. The first would be a battery-electric version with an all-electric range of 200 miles (320 km). The second was to be a hybrid electric vehicle with a range extender, capable of traveling between 40 and 50 miles (64 and 80 km) on electric power before a small gasoline engine would recharge its batteries and power the vehicle, giving it a total range of 400 miles (640 km). However, at the GoingGreen conference in September 2008, Elon Musk—the chief executive officer of Tesla—announced that the company would exclusively produce battery-electric vehicles.

In 2007, Musk appointed Henrik Fisker, known for his work with Aston Martin, as the lead designer of the WhiteStar project. Fisker signed a US$875,000 contract to design the car. The company requested that he design a "sleek, four-door sedan" priced from $50,000–$70,000 (equivalent to $77,636–$108,690 in 2024), and that it be ready between late 2009 and early 2010. Fisker owned a design studio in Orange County, California, which Tesla employees visited to view his designs. Their reactions were generally negative; Ron Lloyd, the vice president of the WhiteStar project, described the designs as "terrible [...] some of the early styles were like a giant egg". When Musk rejected his designs, Fisker attributed the decision to the project's physical constraints, saying, "they wouldn't let me make the car sexy". Shortly after the meetings, Fisker started his own eponymous company and debuted the Fisker Karma in 2008 at the North American International Auto Show. Musk filed a lawsuit against Fisker, accusing him of stealing Tesla's design ideas and using the $875,000 to launch his own company. Fisker won the lawsuit in November 2008, and an arbitrator declared Tesla's claims to be without merit and ordered Tesla to reimburse Fisker's legal fees.

A small team of Tesla engineers went to a Mercedes-Benz car dealership where they test-drove a CLS and an E-Class. Both cars shared a chassis, and the engineers assessed different aspects of the two vehicles, evaluating their positives and negatives. They ultimately preferred the CLS's styling and used it as the baseline for the Model S. After purchasing a CLS, they disassembled it, modified the battery pack of a Tesla Roadster, cut out the CLS's floor, and integrated it with the battery pack. They subsequently put all of its electronics and systems in the CLS's trunk and replaced the interior. After three months of development, the engineers completed a battery-electric version of the CLS. They frequently tested the car on public roads. It had 120 miles (190 km) of all-electric range per charge and weighed more than the Roadster.

In August 2008, Musk hired Franz von Holzhausen—who formerly designed for Mazda—as project WhiteStar's lead designer. Von Holzhausen reviewed Fisker's sketches and clay models but was unimpressed with what he saw, stating that "it was clear [...] that the people [who] had been working on this were novices". To save money, Tesla established its design center within a factory for SpaceX—a company also owned by Musk. As von Holzhausen began designing the exterior of the Model S, Tesla engineers initiated a project to construct another electric version of a CLS. They stripped it to its core, removed the body structure, and extended the wheelbase by four inches (10 cm) to align with early Model S specifications. Within three months, von Holzhausen had designed what would become the production Model S's exterior, and the engineers had begun building a prototype around the design. Given the battery pack's substantial weight, Musk and the team began efforts to minimize the weight of other components. To address this issue, Musk opted to use aluminum instead of steel, stating that the non-battery-pack portion of the vehicle must be lighter than equivalent gasoline vehicles. He noted that the primary challenge was that if aluminum were not used in its construction, the car's performance would be compromised. To accelerate the development of the Model S, one group of engineers worked during the day, while another arrived late evening and worked through the night, both operating within a 3,000 square feet (280 m2) tent in the SpaceX factory.

Tesla debuted a prototype version of the Model S in Hawthorne, California, on March 26, 2009. In August 2009, J. B. Straubel stated that a battery pack with 300-mile (480 km) range would be available, a significant advance at the time. Tesla initially intended to manufacture the Model S in Albuquerque, New Mexico, and later in San Jose, California, but later withdrew from both plans mainly due to financial problems. During the Great Recession, American automaker General Motors decided to abandon the NUMMI facility in 2009, with Toyota soon following. A month after the last car was produced at the manufacturing line in April 2010, Toyota and Tesla announced a partnership and the transfer of the factory. Tesla agreed to purchase a significant portion of the facility for $42 million (equivalent $59 million in 2025), while Toyota invested $50 million (equivalent to $70 million in 2025) in Tesla for a 2.5 percent stake in the company.

During the early 2010s, Musk expanded the engineering teams for the Model S, while von Holzhausen grew the design teams in Los Angeles. The engineers operated in a lab with forty-five personnel. The pre-production version of the Model S, featuring newly stamped body parts from the Fremont factory, a revamped battery pack, and improved power electronics, was completed in the basement of an office in Palo Alto, California. Twelve of the cars were produced; some were sent to suppliers such as Bosch, while others were preserved for testing and design alterations. On June 22, 2012, Tesla invited its employees, select customers, and the press to see the first production Model S in Fremont.

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