Tesla Optimus output rises but lags behind ambitious weekly production targets

Several hundred humanoid units rolled off production lines at Tesla last month, a significant increase from the few dozen manufactured weekly earlier this year. Despite this acceleration, output remains drastically below the company’s stated ambition of producing approximately 20,000 Optimus robots per week.

The Information reported Friday, citing individuals familiar with internal operations, that the intricate design of the robots’ hands has emerged as a primary bottleneck. As Tesla ramps up manufacturing of the newer Optimus V3 model—lighter and equipped with additional cameras—assembly challenges have intensified rather than diminished.

Hand assembly precision issues

Equipment at multiple stations on the production line, particularly those responsible for assembling hands and joints, frequently fails to align parts with sufficient precision. This misalignment results in a higher volume of robots requiring post-production repairs before they can be deployed.

Scaling hand production presents another formidable obstacle. Each hand and forearm contains more than 100 screws and other minute components that must be assembled manually. Furthermore, reports indicate that current hand designs lack durability for sustained use, with touch sensors experiencing reliability failures.

Sensor replacement strategy

To address sensor fragility, Tesla has developed a replaceable “sensing glove” housing the hand’s touch sensors. This design allows technicians to swap out the glove if sensors fail, avoiding the need to replace the entire hand unit. The company intends to integrate this solution into next year’s model.

Manufacturing hurdles are not the sole constraint on deployment speed. The robots still require specific programming and training for individual tasks, with basic functions taking several days to learn. Consequently, Optimus units cannot yet reliably handle a wide variety of jobs without dedicated instruction.

Internal testing and future plans

Tesla currently utilizes most produced robots internally for testing, training, and data collection. Within its factories, these units operate in tightly controlled areas where movements and tasks undergo close supervision, according to The Information.

CEO Elon Musk first announced plans for a humanoid robot in 2021 under the name Tesla Bot, unveiling the first working Optimus prototype the following year. He has since pitched the device as a general-purpose assistant capable of performing factory work, household chores, and babysitting. During an investor call in July, Musk described the potential product as “the biggest product ever.”

Earlier this year, Tesla ceased production of its Model S and Model X electric vehicles at the Fremont, California, facility to allocate space for Optimus manufacturing. While Musk stated earlier this year that sales could begin by late 2027, The Information notes that the company plans to initially lease the robots to commercial customers. Data gathered from robots operating in customer warehouses and factories will be used to refine AI systems.

Tesla did not immediately respond to a request for comment.