Tesla's AI5 chip design nears completion with production plans

Elon Musk has stated that Tesla's next-generation AI5 chip is nearly complete in design, six months after claiming it was finished. Samsung is preparing its Texas factory for trial operations to support AI5 production later in 2026. The chip will be manufactured by both Samsung and TSMC using advanced processes.

Elon Musk recently announced that Tesla's AI5 chip, intended for advanced AI applications including autonomous driving, is 'almost done' with its design phase. This update comes six months after Musk had previously declared the chip 'finished,' indicating a delay in the development timeline. In a post on X, Musk also revealed that early work on the successor AI6 chip is underway, with Tesla aiming for an accelerated nine-month design cycle for future iterations like AI7, AI8, and AI9. He suggested this rapid pace could position Tesla's chips as the highest-volume AI processors globally.

Supporting this progress, Samsung Electronics is ramping up operations at its new semiconductor plant in Taylor, Texas, specifically to produce the AI5 chip. The facility, Samsung's first wafer fabrication plant in the United States spanning 4.85 million square meters, is nearing completion with about 7,000 workers on site, including 1,000 in the office building. According to reports, Samsung plans to start trial operations of extreme ultraviolet (EUV) lithography equipment in March 2026, paving the way for full AI5 production in the latter half of the year. The company is seeking a temporary occupancy permit to begin manufacturing before the plant is entirely finished.

Tesla has partnered with Samsung and Taiwan Semiconductor Manufacturing Company (TSMC) for AI5 production. TSMC will use a 3nm process, while Samsung targets 2nm technology, potentially offering performance advantages. These developments underscore Tesla's aggressive push in AI hardware to enhance its Full Self-Driving and robotics initiatives, though the initial delay highlights challenges in meeting ambitious timelines.

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Illustration of Tesla's Terafab, the largest chip factory, with Optimus robots, solar satellites, and Elon Musk announcing the project.
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Tesla announces massive Terafab chip factory

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Tesla has announced Terafab, described as the largest chip manufacturing facility ever, in collaboration with SpaceX and xAI. The facility aims to produce 1TW of chips per year to support ambitious projects like solar-powered satellites and millions of Optimus robots. Elon Musk stated it requires thousands of acres and over 10GW of power.

Samsung Electro-Mechanics has agreed to a major supply deal with Tesla. The agreement involves FC BGA components worth 16.5 billion dollars for AI6 chips. These chips will support Tesla's self-driving systems and Optimus robot projects.

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Tesla's Terafab chip manufacturing project is set to launch tomorrow, according to a post by Sawyer Merritt. The initiative addresses anticipated supply constraints for advanced chips. Elon Musk has previously highlighted the need for domestic production.

Building on 2025 shareholder meeting announcements and ongoing Giga Texas construction, Tesla plans large-scale Optimus production at Fremont later in 2026—replacing Model S and X lines—followed by a higher-capacity Giga Texas factory in 2027. Elon Musk shared updated timelines recently.

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OpenAI is fast-tracking production of an AI-focused smartphone, with mass production set to begin in the first half of 2027. Analyst Ming-Chi Kuo predicts the company could manufacture 30 million units over 2027 and 2028. The device aims to use AI agents in place of traditional apps.

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