Skip to content 
Tesla’s Cybertruck isn’t just a statement in styling — it’s a revolution in vehicle architecture, manufacturing, and electrical engineering. In a rare roundtable hosted at Giga Texas, five top Tesla executives joined Sandy Munro to unpack the innovations underpinning the Cybertruck platform. From its controversial exoskeleton to game-changing 48-volt architecture and software-defined vehicle systems, the Cybertruck embodies Tesla’s philosophy of lean, vertically integrated engineering.
Let’s breaks down the highlights and offer automotive engineers, EV enthusiasts, and manufacturing leaders a unique window into how Tesla is rewriting the rules.
Full System Thinking: Tesla’s Software + Hardware Integration
Tesla’s core advantage isn’t just design or batteries — it’s systemic integration. Pete Bannon, lead of low-voltage electronics and Autopilot hardware, emphasized that Tesla’s software isn’t available to OEMs for one reason: it’s inseparable from the hardware.
Their software-defined architecture allows Tesla to run a gigabit Ethernet loop throughout the Cybertruck, replacing legacy CAN bus complexity with a low-mass, high-bandwidth network. This switch dramatically reduces wiring weight, simplifies debugging, and provides real-time microsecond synchronization for features like active noise cancellation and dynamic brake control.
A gigabit Ethernet loop combined with 48V architecture ultimately means few controllers, fewer wires, and faster development cycles.
48-Volt Architecture: The Next Evolution
The shift to 48 volts isn’t just about efficiency — it’s about capability. While earlier Teslas stuck with 12V systems due to manufacturing inertia, the Cybertruck represents a clean-sheet move to 48V, enabling lighter wiring, smaller fuses, and integrated jump-start capabilities.
Key takeaways:
- High-power harness mass cut by 84%
- Etherloop communication unifies control across the vehicle
- Simplified debug and modular control units reduce cost and complexity
Tesla’s approach exemplifies lean engineering: reduce system elements while enhancing capability.
Exoskeleton & Materials: Function Drives Form
Tesla’s bold exoskeleton isn’t just an aesthetic gamble. It’s a structural leap. Built from a custom “HFS” (Hard Freaking Stainless) alloy, it balances ductility, strength, and corrosion resistance. Tesla also chose air bending (not stamping) to form cold-hardened panels without surface bruising. This process enhances durability while also reducing finishing costs.
Additionally, Tesla developed:
- The world’s largest hot-stamped boron steel door ring
- A powder-coated visible B-surface, eliminating body side outers
- Massive giga-castings — 6,500T front, 9,000T rear
These parts integrate structure and crashworthiness, replacing dozens of components with a single casting.
Giga-Press and Die Optimization: Cast Smarter, Not Bigger
Unlike many OEMs, Tesla builds both castings and the die sets in-house. Their design team collaborates in real time with die engineers, optimizing cooling channels and metal flow to reduce tonnage requirements.
As an example, the front casting initially required 8,000 tons. After redesign, however, Tesla achieved it with Model Y-grade tooling. This lean casting approach lowers cost, enhances cycle time, and delivers higher repeatability — which, of course, is ideal for scaling.
Scalable Powertrains: From Single to Tri-Motor
Additionally, the Cybertruck is built on a flexible powertrain platform:
- Rear-wheel drive (RWD): 315 hp
- Dual-motor AWD: Mid-tier balance
- Tri-motor AWD: 845 hp, 0–60 in 2.6s
All configurations use shared inverter designs and hairpin motors, demonstrating Tesla’s obsession with part standardization and cost compression.
Despite its mass (~6,800 lbs), the Cybertruck retains high performance and impressive towing (up to 11,000 lbs) for an EV thanks to its advanced motor control and regenerative braking system, which adapts to trailer mass in real-time.
Steer-by-Wire + Rear Steer: Big Truck, Small Car Feel
Tesla’s implementation of steer-by-wire and rear steering gives the Cybertruck surprising agility. Dual 48V pinion-drive motors control the front axle redundantly, while a third identical motor handles the rear steer — up to 10° of turn — reducing turning radius and improving handling at low speeds.
Consequently, locked-to-lock steering requires just 340°, enhancing driver comfort.
As for our engineering takeaway? Rear steer transforms the feel of a full-size pickup into something more akin to a sports sedan.
Bidirectional Charging + 400V/800V Native Support
Tesla’s next-gen PCS2 (Power Conversion System) packs serious capability:
- 11.5 kW bidirectional output for home backup
- Native 400V and 800V charging without step-up conversion
- All planar magnetics, no hand-wound inductors
The truck also supports 240V output from the bed, allowing it to charge other EVs or power tools — ideal for worksite or off-grid utility. Quite frankly, you can power a house with the Tesla Cybertruck.
Extended Range Battery: Optional, Practical, Efficient
Need more range? The optional battery pack sits above the rear axle in the bed, enabling over 460 miles of range. Designed as a modular add-on, it supports those who tow long distances without forcing everyone to carry extra battery mass.
This modular mindset supports sustainability by aligning resources with real-world needs.
Serviceability and Structural Battery Upgrades
Tesla’s service strategy includes:
- Quick-change HEPA filters
- Tool-free access to trunk/frunk systems
- Evolved structural battery vs Model Y — flatter, lighter, better ground clearance
And yes, those are the new 4680 dry cells — now made in Texas with 9% higher energy density.
Key Takeaways for Engineers & Investors
- 48V + Etherloop = fewer controllers, better debugging, and safer design
- Die-casting + in-house stamping reduces part count and manufacturing cost
- Steer-by-wire + rear steer deliver unexpected agility
- Bidirectional PCS and native 800V charging future-proof Tesla’s powertrain
Final Thoughts: Tesla Isn’t Just Building a Truck
The Cybertruck embodies Tesla’s mission to rethink the vehicle from the ground up. It’s not only just a product. But it’s also a platform, a case study in lean engineering, and a glimpse at the next decade of automotive design.
Tesla has replaced conventional complexity with elegant integration. For engineers and investors alike, the message is clear: the future belongs to those who design for it today.
Explore more teardown insights and the latest engineering breakdowns with Munro.