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Tesla continues to push the boundaries of vehicle design, but there’s always room to rethink tradition. In this expert teardown discussion, Munro & Associates explores unconventional paths Tesla might take with its E1 platform—specifically reimagining steering systems and shedding unnecessary weight. These insights target two critical areas of EV evolution: intuitive control and leaner, more efficient design.
Rethinking the Steering Wheel: A Relic of the Past?
The steering wheel, as we know it, has barely evolved since its introduction. Born out of a need to guide early motorized vehicles, it replaced ropes, reins, and tillers used with horses and primitive machines. But with the shift toward drive-by-wire systems and increasingly software-controlled EV platforms, it’s worth asking—do we still need a steering wheel at all?
Munro suggests Tesla consider moving toward a center stick design, like that used in aircraft cockpits. This concept was successfully tested in the Paradigm, a lightweight airplane developed by Munro & Associates. The center stick allowed either occupant to control direction while freeing up space and simplifying cockpit layout. Transferring this philosophy to EVs could enhance ergonomic design, reduce mechanical complexity, and open new interior layout possibilities.
While full mind-controlled navigation remains a vision for the distant future, moving away from the traditional steering wheel is a bold step Tesla could take to signal its commitment to true innovation. The goal isn’t novelty for novelty’s sake, but a genuine opportunity to rethink human-machine interfaces for the autonomous, software-first era.
How Lighter Wheels Lead to Greater Range
Weight remains one of the biggest enemies of EV range and performance. Even marginal reductions can result in meaningful improvements in efficiency and cost. One easy target? Tires and rims.
During the teardown of the Tesla Model Y, Munro observed that the stock tires are nearly as heavy as slicks used on race cars—surprisingly bulky for a production EV. In contrast, a lighter aftermarket tire and rim combination tested during the teardown proved easier to handle and significantly reduced rolling resistance. That means less friction and more miles per kilowatt-hour.
For Tesla owners, this points to immediate aftermarket options to improve performance. For Tesla engineers, it signals an opportunity to rethink tire and wheel specs from the factory floor forward.
Mega Castings: The Case for a Front-End Redesign
Tesla’s use of rear-end mega castings has already revolutionized body-in-white manufacturing, but Munro believes the same principle should be applied to the front of the vehicle. Currently, Tesla’s front end still relies on multiple components—shotgun rails, brackets, and other sub-assemblies—that could be consolidated into a single cast piece.
Such a redesign wouldn’t just cut weight; it would reduce complexity, cost, and the likelihood of quality issues during assembly. By reducing part counts and welds, Tesla could further accelerate its manufacturing process—delivering on the promise of lean design and lean manufacturing that Munro has long championed.
Carbon Fiber Battery Trays: An Overdue Upgrade
Another overlooked component with high weight potential is the battery tray. Traditionally made of steel or aluminum, it represents one of the heaviest structures in the EV platform. But German suppliers such as Altech and SGL Carbon are now producing carbon fiber battery trays that offer a compelling alternative.
Carbon fiber offers high strength at a fraction of the weight, making it ideal for structural support of heavy battery packs. Incorporating these trays into Tesla’s design would not only reduce curb weight but also potentially improve crash performance and energy absorption characteristics.
One Gram Per Day: A Practical Engineering Mantra
In a nod to Asian manufacturing discipline, Munro shares a deceptively simple philosophy: “One gram, every day.” The rule is straightforward—every engineer should aim to reduce the weight of their assigned component by just one gram per day.
This incremental mindset builds a culture of continuous improvement. Multiply that by hundreds of engineers over the course of a year, and the cumulative effect becomes substantial. It encourages deep inspection of every fastener, bracket, and panel—searching for smarter materials, integrated functions, or outright eliminations.
Tesla E1: Innovating the Way Forward
Tesla has always positioned itself as a company unafraid to disrupt the status quo. With the E1 platform on the horizon, it has another opportunity to do just that. Replacing the steering wheel with a center stick, incorporating carbon fiber and additional mega castings, and pushing for gram-level weight savings aren’t just ideas—they’re transformative strategies that align with Tesla’s DNA.
As EVs move toward autonomy, software-defined platforms, and ultra-efficient architectures, it’s time to challenge old assumptions. And as always, Munro & Associates will be there to break down, analyze, and improve every innovation.
Stay tuned for more expert EV insights, teardown breakdowns, and design reviews from the team at Munro.