In Tesla's third-quarter earnings call, CEO Elon Musk discussed the challenges and anticipations surrounding the Cybertruck, arguably Tesla's most anticipated vehicle. Here are the major takeaways.
"We Dug Our Grave"
In a candid moment, Musk admitted, "We dug our grave for Cybertruck." This poignant statement underscores the formidable challenges Tesla faces in producing this revolutionary vehicle. Musk described the Cybertruck as a rare gem, a product that comes along "once in a long while." Such unique products are inherently difficult to scale, bring to market, and ensure profitability.
Musk was emphatic about the hurdles Tesla faces with the Cybertruck. "There will be enormous challenges in reaching volume production with the Cybertruck," he said. He attributed these challenges to the vehicle's innovative technology and its vast differences compared to other vehicles.
Making a distinction between creating and mass-producing a prototype, Musk remarked, "Prototypes are easy; production is hard." Emphasizing the immense difficulty of the latter, he pointed out that it's "10,000% harder to get to volume production than to make a prototype."
Musk drew on his extensive experience, mentioning that reaching volume and prosperity would require immense "blood, sweat, and tears." While he's faced similar challenges with other Tesla vehicles, the Cybertruck presents its unique set of challenges.
Cybertruck Preorders & Annual Production
While Musk labeled the Cybertruck as potentially Tesla's "best product ever," he was clear about the financial trajectory. He estimates it may take "a year to 18 months before it is a significant positive cash flow contributor." He noted that the demand for the Cybertruck isn't an issue, with over "1 million people who've reserved the car." The challenge lies in producing it at an affordable price.
When asked about delivery expectations for 2024, Musk's response was cautiously optimistic. He admitted the difficulty of making accurate predictions due to the radical nature of the Cybertruck. "If you want to do something radical and innovative...it is extremely difficult because there's nothing to copy," Musk stated. However, he gave a ballpark figure, projecting that by 2025, Tesla would achieve a production rate of "roughly 0.25 million Cybertrucks a year."
Unofficial Specifications
Since its 2019 debut, the Cybertruck's specs have shifted. Influenced by rivals like Rivian R1T and Ford F-150 Lightning, Tesla adjusted dimensions. Initially 232 inches long and 80 inches wide, recent enthusiasts' measurements suggest a width of 78 inches, closer to Tesla's Model S.
Delivery Event
Amid spec uncertainties, the Cybertruck remains a hotly anticipated vehicle. Musk's frank discussion paints a picture of the hurdles ahead. However, Tesla announced its Cybertruck delivery event on November 30th at Giga Texas.
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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)
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