June 23, 2025 – In a significant development for Tesla's autonomous driving ambitions, detailed specifications and production plans for the highly anticipated Hardware 5 (HW5) Full Self-Driving (FSD) computer – internally dubbed "AI5" – have reportedly leaked, revealing a substantial performance leap and a strategic dual-sourcing manufacturing approach involving industry giants TSMC and Samsung Foundry.
According to multiple sources familiar with the matter, Tesla's AI5 chip is designed to deliver a staggering five-fold increase in raw processing power compared to the current HW4 system powering newer vehicles. This exponential jump is seen as critical for handling the immense computational demands of Tesla's evolving "Vision-only" neural networks and the eventual goal of unsupervised autonomous operation.
Key Leaked Specifications & Details:
- Performance Target: A core objective is achieving 5x the performance of HW4's dual-chip system. This target encompasses both neural network inference capabilities crucial for real-time perception and decision-making, and general computing power for sensor fusion and path planning.
- Architecture: The AI5 is expected to utilize a more advanced process node than HW4's 7nm/5nm hybrid. While specifics are guarded, leaks point towards TSMC utilizing its cutting-edge N3P (3nm) or potentially even N2 (2nm) process, while Samsung employs its latest SF3 (3nm GAA) technology. This shift to more advanced nodes is a primary driver of the performance and efficiency gains.
- Dual-Sourcing Strategy: In a major shift, Tesla is reportedly splitting production between TSMC (Taiwan Semiconductor Manufacturing Company) and Samsung Electronics Foundry. This move is interpreted as a strategic effort to mitigate supply chain risks, secure sufficient production capacity for the high-volume rollout expected with future models like the "Robotaxi," and potentially leverage competitive pricing between the two foundry leaders. Production sources indicate Samsung Foundry has secured a significant portion of the initial AI5 orders.
- Integration & Form Factor: The AI5 system is expected to maintain a similar physical footprint to HW4, allowing for retrofitting potential (though Tesla's commitment to retrofits remains uncertain). Integration focuses on maximizing performance per watt and thermal efficiency.
- "AI5" Nomenclature: The internal project name "AI5" underscores Tesla's framing of the hardware as a dedicated artificial intelligence accelerator, central to its autonomous driving ecosystem.
Driving Towards "Driverless"?
The timing of these leaks coincides with other reports suggesting Tesla is accelerating real-world testing of its FSD capabilities. Highly credible sources report sightings of seemingly driverless Tesla Model Y vehicles actively navigating complex urban environments in specific test zones. While the software enabling such operation is distinct from the hardware, the immense computational requirements of truly unsupervised driving make the power of HW5/AI5 not just beneficial, but likely essential.
Industry Implications:
A successful HW5/AI5 launch would solidify Tesla's position as having one of the most powerful dedicated automotive AI compute platforms globally. The dual-sourcing deal with TSMC and Samsung is also a significant win for Samsung Foundry, demonstrating its ability to compete for the most demanding automotive AI chips. For TSMC, it reaffirms its leadership in cutting-edge semiconductor manufacturing.
Tesla's Silence & Next Steps:
As usual, Tesla has not officially commented on the leaks or the specifics of HW5. However, if the leaked specifications and production plans hold true, HW5/AI5 represents a monumental step in Tesla's FSD journey. Integration into new vehicles could begin as early as late 2026 or 2027, potentially debuting alongside the much-discussed dedicated Robotaxi platform.
The Bottom Line: The leaked specs for Tesla's HW5 "AI5" computer paint a picture of dramatically enhanced capability, crucial for unlocking higher levels of autonomy. Partnering with both TSMC and Samsung for manufacturing highlights Tesla's serious commitment to scaling its FSD ambitions while managing risk. If these leaks prove accurate, the hardware foundation for Tesla's next major FSD leap is taking shape.
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