A few weeks ago, we reported that Tesla will deliver its first HW4 vehicles without the suspected additional cameras. Shortly after, Twitter user Kilowatts ventured into one of Tesla’s vehicle lots and was able to snap photos of some of the first Teslas with hardware 4.0.
Delivery of HW4 Model X
A poster on Reddit shared pictures and video of his 2023 Model X delivery, showcasing hardware 4.0. According to their post, the vehicle was built on February 25th and delivered March 5th, a mere 10 days after being built.
Software Still a Work In Progress
Teslas with hardware 4.0 are missing visualizations, TACC and Autopilot right now
jasondclinton/Reddit
However, several features on his vehicle are currently unavailable as Tesla appears to still be developing and testing software for HW4. These features include almost everything that utilizes the vehicle's cameras, including Autopilot and Traffic Aware Cruise Control (TACC). Full Self-Driving Beta (FSD Beta) is also disabled.
The visualizations on-screen are also absent, the vehicle displays almost no visualizations of any kind. According to the author of the post, only road markings are visible.
The vehicle does not show any details confirming it has HW4 in any of the usual places such as the software tab, in the 'additional vehicle information' dialog, or in Tesla's Service menu. However, the owner says that Tesla themselves confirmed that the vehicle is equipped with Tesla's latest FSD hardware and the author's photos confirm the presence of the new cameras.
HW4 Timeline for Other Teslas
While Tesla continues to work on the software for HW4, we’re anticipating the Model 3 and Model Y vehicles to follow with HW4 deliveries at some point this year. Tesla’s “Project Highland” is making way, but Tesla may add hardware 4.0 to the Cybertruck first, as the new hardware may be constrained due to ramping production.
Retrofits for HW4
Tesla CEO Elon Musk has said that HW4 will not be available for retrofits. He’s said that as long as HW3 remains safer than a human then there’s no need for an upgrade. The entire computer has been rebuilt and rearranged, making it much more difficult to pop it into HW3 vehicles.
After Greentheonly’s leak about HW4 last month, Munro Live shared an in-depth video explaining every detail of HW4 and what to expect. Additionally, they went over why retrofits are not feasible.
Update
Update: The owner, Jason has updated their Reddit post to provide an update on some of the missing ADAS features. He noticed that his rear camera was failing and that he could reset it in Tesla's Service Mode.
Resetting the camera would bring it back online, however, it crashes again just minutes later. Jason was able to have the camera online long enough to confirm that Autopilot was available if the camera was working. However, as soon as it crashes, Autopilot and other features would go offline, even if they didn't completely depend on the rear camera.
For example, visualizations would appear, but as the rear camera crashed, they would completely disappear, even if the objects that were in front of the car.
Jason said that Navigate on Autopilot, TACC and visualizations appeared to be available while the rear camera was online, but it wasn't clear whether all features were available such as AutoPark, Summon and FSD Beta.
This appears to be a software-related issue, but it's not clear at this time whether it's affecting everyone with hardware 4.0 or if it's limited to some vehicles.
Update 2
Update 2: The vehicle in question has now received another software update, version 2023.201, which contains "bug fixes."
This update has fixed the issue with the rear camera and the vehicle has regained access to Autopilot, TACC, vehicle visualizations and other features, although AutoPark and FSD Beta are still unavailable. This update addresses the larger concerns and reestablishes the major features of the vehicle, however, we hope the additional functionality is restored soon.
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Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
Tesla has pioneered the use of single-piece castings for the front and rear sections of their vehicles, thanks to its innovative Gigapress process. Many automakers are now following suit, as this approach allows the crash structure to be integrated directly into the casting.
This makes the castings not only safer but also easier to manufacture in a single step, reducing costs and improving repairability. For example, replacing the entire rear frame of a Cybertruck is estimated to cost under $10,000 USD, with most of the expense coming from labor, according to estimates shared on X after high-speed rear collisions.
These insights come from Sandy Munro’s interview (posted below) with Lars Moravy, Tesla’s VP of Vehicle Engineering, highlighting how these advancements contribute to the improvements in Tesla’s latest vehicles, including the New Model Y.
However, with the new Model Y, Tesla has decided to go a different route and eliminated the front gigacast.
No Front Casting
Tesla’s factories aren’t equipped to produce both front and rear castings for the Model Y. Only Giga Texas and Giga Berlin used structural battery packs, but these were quickly phased out due to the underwhelming performance of the first-generation 4680 battery.
Tesla has gone back to building a common body across the globe, increasing part interchangeability and reducing supply chain complexity across the four factories that produce the Model Y. They’ve instead improved and reduced the number of unique parts up front to help simplify assembly and repair.
There is still potential for Tesla to switch back to using a front and rear casting - especially with their innovative unboxed assembly method. However, that will also require Tesla to begin using a structural battery pack again, which could potentially happen in the future with new battery technology.
Rear Casting Improvements
The rear casting has been completely redesigned, shedding 7 kg (15.4 lbs) and cutting machining time in half. Originally weighing around 67 kg (147 lbs), the new casting is now approximately 60 kg (132 lbs).
This 15% weight reduction improves both vehicle dynamics and range while also increasing the rear structure’s stiffness, reducing body flex during maneuvers.
Tesla leveraged its in-house fluid dynamics software to optimize the design, resulting in castings that resemble organic structures in some areas and flowing river patterns in others. Additionally, manufacturing efficiency has dramatically improved—the casting process, which originally took 180 seconds per part, has been reduced to just 75 seconds, a nearly 60% time reduction per unit.
Advancements in die-casting machines and cooling systems have allowed @Tesla to dramatically reduce cycle times and improve dimensional stability. pic.twitter.com/WB5ji67rvV
Tesla’s new casting method incorporates conformal cooling, which cools the die directly within the gigapress. Tesla has been refining the die-casting machines and collaborating with manufacturers to improve the gigapress process.
In 2023, Tesla patented a thermal control unit for the casting process. This system uses real-time temperature analysis and precise mixing of metal streams to optimize casting quality. SETI Park, which covers Tesla’s manufacturing patents on X, offers a great series for those interested in learning more.
The new system allows Tesla to control the flow of cooling liquid, precisely directing water to different parts of the die, cooling them at varying rates. This enables faster material flow and quicker cooling, improving both dimensional stability and the speed of removing the part from the press for the next stage.
With these new process improvements, Tesla now rolls out a new Model Y at Giga Berlin, Giga Texas, and Fremont every 43 seconds—an astounding achievement in auto manufacturing. Meanwhile, Giga Shanghai operates two Model Y lines, delivering a completed vehicle every 35 seconds.
![A Look at the Tesla Cybertruck’s Crumple Zones [VIDEO]](https://www.notateslaapp.com/img/containers/article_images/cybertruck/cybertruck-crash-test.webp/e43ef2433bd6e44ae8db63421604a4fb/cybertruck-crash-test.jpg)
