Tesla Semi Enters Full-Scale Production

Rex Ballard
5 hours ago
6 min read

A Game-Changer for the Trucking Industry

Tesla has officially announced that its long-awaited Semi electric truck is transitioning to high-volume production this year at its Gigafactory Nevada facility, marking a significant milestone in the electrification of heavy-duty transportation. CEO Elon Musk confirmed the ramp-up on X, stating that production will scale to meet growing demand, with customer deliveries slated to begin in the first half of 2026. This move comes after years of development, testing, and refinements, positioning the Semi as a competitive alternative to traditional diesel trucks.

2028 Tesla Semi - photo www.teslarati.com

Background on the Tesla Semi

The Tesla Semi was first unveiled in 2017 as a Class 8 electric truck promising revolutionary efficiency, range, and performance. Initial production was delayed multiple times due to technical challenges, supply chain issues, and design updates. Limited manufacturing began in 2022, with the first units delivered to PepsiCo in December of that year. Since then, Tesla has produced around 70 units, primarily for internal use and select customers, while constructing a dedicated 1.7-million-square-foot factory adjacent to Gigafactory Nevada capable of outputting up to 50,000 Semis annually once fully operational. The latest redesign, revealed at Tesla's 2025 shareholder meeting, includes improved aerodynamics, a new chassis, and Model Y-inspired headlights to enhance efficiency and payload capacity.

Tesla is promising to revolutionize trucking - image www.telsaoracle.com

Initial Pilot Programs and Participating Companies

Before full-scale production, the Tesla Semi underwent extensive real-world testing through pilot programs with major logistics and shipping companies. These trials demonstrated the truck's reliability, efficiency, and suitability for demanding routes.

PepsiCo: One of the earliest adopters, PepsiCo received the first production Semis in 2022 and has since logged impressive performance, with hauls exceeding 425 miles on a single charge under full load. The company has integrated the trucks into its fleet for beverage distribution, providing valuable data on energy consumption and uptime.
ArcBest: In a three-week over-the-road pilot in 2025, the Semi covered 4,494 miles, averaging 321 miles per day with 1.55 kWh per mile efficiency. It handled challenging terrain like Donner Pass, earning praise from drivers for comfort and safety features.
thyssenkrupp Supply Chain Services: Completed a three-week demo at a California hub, calling the Semi a "natural fit" for their operations due to its performance and low operating costs.
DHL: Added a Semi to its Central California fleet in late 2025, following a pilot involving 390-mile long-haul routes at 75,000 pounds gross combined weight. DHL plans to expand its Semi fleet in 2026 as part of its zero-emissions goal by 2050.
Uber Freight: Partnered with carriers for a two-month pilot in 2025, showcasing the Semi's reliability over 394 hours of operation. This led to the launch of Uber Freight's Dedicated EV Fleet Accelerator Program, offering subsidies for Semi purchases.

Other early reservation holders like UPS and Walmart participated in initial discussions, but recent pilots have focused on operational validation with the updated design.

Basic Specifications of the Tesla Semi

Tesla recently updated its Semi website with final production specs, offering two trims to cater to different fleet needs:

Feature	Standard Range Trim	Long Range Trim
Range (at 82,000 lbs GCW)	325 miles	500 miles
Curb Weight	Under 20,000 lbs	23,000 lbs
Energy Consumption	1.7 kWh per mile	1.7 kWh per mile
Drive System	Three independent rear-axle motors, up to 800 kW power	Same
Power Take-Off (PTO)	Up to 25 kW	Same
Charging	60% range recovery in 30 minutes via MCS 3.2 connectors; up to 1.2 MW peak	Same

These specs emphasize efficiency, with the Semi's tri-motor setup providing rapid acceleration (0-60 mph in 20 seconds fully loaded) and regenerative braking for energy recovery. The cab features a centered driver seat for optimal visibility and advanced active safety systems.

Anticipated Cost Advantages Over Conventional Semi Trucks

The Tesla Semi promises substantial savings over diesel counterparts, making it attractive for cost-conscious fleets. Electricity costs range from $0.15 to $0.25 per mile, 60-70% cheaper than diesel's $0.50 to $0.70 per mile. Maintenance is reduced due to fewer moving parts—no engine, transmission, or after-treatment systems—coupled with remote diagnostics and over-the-air (OTA) updates that minimize downtime. Fleets can achieve positive returns on investment before the typical 7-10 year diesel replacement cycle, with improved uptime further boosting profitability. Real-world data from pilots, like PepsiCo's, supports these claims, showing consistent efficiency even on hilly routes.

Annual maintenance costs for diesel semis average $15,000-$25,000 (or $0.12-$0.20 per mile at 100,000 miles), driven by engine repairs and complex systems. For the Tesla Semi, estimates indicate 20-50% lower costs, at $7,500-$15,000 annually (or $0.09-$0.17 per mile), thanks to simplified electric powertrains and regenerative braking. This could yield $5,000-$15,000 in yearly savings per truck.

Production Targets and Existing Orders

Tesla aims to produce 50,000 Semis annually by late 2026, starting with limited output in the first half of the year for internal fleets before external deliveries. The Nevada factory is nearing completion, with equipment installation ongoing.

Orders have surged, particularly through incentives. California has reserved nearly 1,000 vouchers worth $165 million under its Hybrid and Zero-Emission Truck and Bus Voucher Incentive Project (HVIP), positioning Tesla to dominate early electric truck subsidies. Early reservations from 2017 totaled around 270 units, including 100 from PepsiCo. While exact current order numbers aren't public, state data indicates strong demand, with many fulfillments expected in late 2026.

Initial orders come from a mix of carriers, not exclusively favoring short-haul routes. While some like PepsiCo use the Semi for shorter hauls (e.g., 100 miles for heavy soda loads), pilots and orders demonstrate viability for long-haul operations. For instance, PepsiCo achieves 425-mile hauls for lighter loads, DHL tested 390-mile routes, and ArcBest averaged 321 miles per day over long distances. Companies like UPS, FedEx, and Anheuser-Busch have placed significant orders, with many planning to integrate the Semi into both regional (short-haul, under 250 miles) and over-the-road (long-haul, over 250 miles) fleets, leveraging the 500-mile range trim for extended routes. This balanced interest reflects the Semi's design for versatility, though early adopters are proving its long-haul capabilities to address skepticism about battery range in heavy-duty trucking.

Financial analysts are predicting that Semi production will contribute between $400 million to $2 billion of additional revenue for 2026 depending on how quickly Tesla can ramp up production and avoid delays that have historically plagued new production lines.

Scenario	Units	Avg. Price	Add'l Revenue	Gross Profit (15–20%)	Net Profit Est.
Conservative	1,400	$270k	$378M	$57–$76M	$30–$50M
Moderate	5,000	$270k	$1.35B	$203–$270M	$100–$150M
Optimistic	10,000	$270k	$2.7B	$405–$540M	$200–$300M

Charging Infrastructure for the Tesla Semi

Tesla is actively expanding its Megacharger network to support the Semi's rollout. As of early 2026, infrastructure development is progressing, with the first public Megacharger station blueprint revealed in 2025 for a site in Carson, CA. A major partnership with Pilot Travel Centers, the nation's largest truck stop operator, will deploy high-power charging stations at select locations starting in summer 2026, focusing on key corridors like I-5 and I-10 in states including California, Georgia, Nevada, New Mexico, and Texas. Tesla plans 46 stations by 2027, featuring over 300 Megawatt-capable stalls capable of 1.2 MW charging, enabling up to 400 miles of range in 30 minutes. Construction is underway, with internal sites at Gigafactory Nevada already operational for testing. Customer-specific depots, like PepsiCo's, are also being built, and Tesla anticipates more as deliveries ramp up. This network aims to make the Semi viable for long-haul trucking, though full coverage will develop progressively through 2026 and beyond.

Availability of Full Self-Driving (FSD)

The Tesla Semi includes the necessary hardware for advanced driver assistance systems, such as cameras and sensors for potential Full Self-Driving (FSD) capabilities. However, Tesla has not confirmed FSD availability for the production Semi at launch. Current models feature active safety systems like automatic emergency braking and adaptive cruise control, but full unsupervised autonomy—available on Tesla's passenger vehicles via subscription in select regions—remains unannounced for the truck. Software development for heavy-duty applications is ongoing, and regulatory approvals may delay rollout. Tesla's focus for initial deliveries appears to be on core performance and efficiency, with autonomy potentially added via future OTA updates.

This announcement underscores Tesla's push into commercial EVs, potentially disrupting the trucking industry amid rising fuel costs and emissions regulations. As production ramps, the Semi could accelerate the shift to sustainable logistics. As FSD comes on line it is expected to drive sharp increases in both revenue and profits for Tesla.

https://www.youtube.com/watch?v=U7Em2I7-DJ0