Tesla Struggles With Optimus Production As Humanoid Robot Assembly Requires Extensive Manual Labor

The Verge•Published: Sep 25, 2026 10:31 PM IST

Tesla is encountering significant manufacturing challenges in its effort to mass-produce the Optimus humanoid robot, falling well short of its ambitious production goals. While the company repurposed existing vehicle assembly lines, the high precision required for the robot's intricate components has forced a reliance on manual labor for assembly.

Production Volume: Tesla produced only several hundred units last month, a far cry from the company's long-term goal of manufacturing 20,000 robots per week.
Assembly Complexity: The V3 Optimus model features hands and forearms containing over 100 small components that currently require human workers to assemble by hand.
Manufacturing Snags: Repurposing Model S and Model X production lines has created difficulties in aligning parts precisely, as robot components require much tighter tolerances than automotive parts.

The Context & Background

Tesla has faced years of delays regarding the Optimus project, despite CEO Elon Musk positioning the robot as the company's most significant future product. Currently, the robots are limited to internal tasks at Tesla facilities, with plans to eventually lease the units to collect training data for further development.

Why it matters:The manufacturing difficulties highlight the immense gap between conceptual robotics and scalable industrial production. As Tesla struggles to automate the assembly of its own robots, the broader industry faces questions about the feasibility of mass-market humanoid deployment and the economic viability of replacing human labor with current robotic technology.

Enjoyed this 2-minute breakdown?

Share it with your colleagues and friends!