Samsung has completed the tape-out process for Tesla’s next-generation AI5 chip, marking another major step toward production. Back in mid-April, Tesla CEO Elon Musk announced on X that the AI5 chip had completed tape-out. At the time, the milestone only covered Tesla’s side of the process, meaning the chip’s design had been finalized by the company.
However, chip production involves two stages. After the designer completes the blueprint, the manufacturer must convert it into a production-ready design. Samsung has now confirmed that it has finished its part of the tape-out process as well.
As a result, production of the AI5 chip is expected to start by the end of this year. However, the company is not likely to reach mass production capacity until at least mid-2027. Samsung also confirmed another key detail about the project. The AI5 chip will use the company’s new 2nm-class SF2T manufacturing process.
There had been some confusion about the manufacturing node in recent months. Some reports suggested that Tesla’s next-generation chip would use a 3nm process, while others pointed to a 2nm technology. Samsung’s latest confirmation now settles that debate.
The chips will be produced at Samsung’s semiconductor facility in Taylor, Texas. The factory’s 2nm production lines will manufacture Tesla’s AI5 processors. The development also suggests that Tesla’s future AI6 chips could use the same 2nm SF2T process.
Tesla’s custom chips play a major role in its advanced driver assistance systems and full self-driving technology. The company has faced criticism over FSD support on older hardware in recent years. Because of that, Tesla appears to be building more powerful, future-ready chips to avoid similar issues.
At the same time, Tesla continues to spread its supply chain across multiple partners. The company works with both Samsung and Taiwan Semiconductor Manufacturing Company, better known as TSMC, for chip production.
By partnering with two of the world’s biggest chipmakers, Tesla can reduce supply risks and secure a stable flow of processors. This strategy could also help the company deal with ongoing geopolitical tensions involving China, Taiwan, and the United States.
