Tesla scales Optimus humanoid robot production amid technical hurdles

Tesla is ramping up production of its third-generation Optimus humanoid robot, increasing weekly output from a few dozen to several hundred units. The company aims to reach 1,000 units per week by the end of 2026, with long-term goals of 20,000 units per week.

However, the scaling process faces significant technical and logistical hurdles. A primary bottleneck is the assembly of the robot's hands and forearms, which consist of over 100 small components and screws that currently require manual assembly. Automated production lines have struggled with the precision required for these tight-tolerance parts, leading to frequent rework. Additionally, touch sensors in the hands have shown reliability issues, prompting Tesla to develop a replaceable “sensing glove” to avoid replacing entire hand assemblies.

Beyond hardware, Tesla faces challenges in AI training and workforce relations. The robots currently require specific programming for controlled environments and struggle with unpredictable tasks. To gather necessary imitation learning data, Tesla has used specialized suits to record human movements, a practice that has met resistance from workers in Texas and California who fear the robots are intended to replace them. Tesla is also heavily reliant on Chinese suppliers for key electromechanical components, including joint modules and actuators.