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Munro & Associates continues to uncover the secrets of cutting-edge electric vehicle design. In their latest release, they shared exclusive closeups of the Tesla Cybertruck Dual Motor platform. The vehicle appears to be a test unit, but the details still speak volumes. Each image and insight highlights how Tesla keeps evolving its engineering.
For automotive engineers, EV enthusiasts, and forward-thinking investors, this Cybertruck teardown offers a clear direction. Tesla is moving toward higher integration, smarter packaging, and an aggressive push for manufacturability and cost efficiency.
Let’s break down what these changes mean in practice.
Frunk Exploration: Integration Meets Purpose
The analysis begins under the hood—or rather, in the frunk—of the Cybertruck. While the presence of jumper cables and a test jig suggests the unit is pre-production, the components on display still speak volumes.
A notable highlight is the new iteration of Tesla’s super manifold system, labeled “Super Manifold V2.” This cooling architecture, more advanced than what was seen in previous teardowns of the Model S or Model Y, suggests that Tesla is not resting on its laurels when it comes to thermal management. The manifold design appears refined for better integration and layout efficiency.
Further, the placement and redesign of the receiver dryer or accumulator indicate Tesla’s ongoing push to optimize the HVAC layout. Unlike the roll-formed tubular assemblies in the Model Y or the superbeam structure in the Model S, this vehicle uses what appears to be a permanent mold die casting to span across the shock towers. Magnesium may be a likely candidate for this casting, thanks to its shock absorption and light-weight properties—an ideal match for NVH (noise, vibration, harshness) management.
Next-Gen Cooling and Mounting Strategy
Another critical advancement is visible in how Tesla mounts the EAC compressor. Previously, the compressor’s bracket was a separate piece. In this Cybertruck, it seems to have been integrated directly into the casting, reducing part count and improving vibration isolation. This “self-mounting” philosophy—where a component’s housing doubles as a structural mount—is textbook lean design.
Tesla has also oriented many components along the X-axis instead of the typical Z-axis, which deviates from common practice. This orientation might complicate robot assembly in other vehicles but is likely optimized here for ease of maintenance and better packaging beneath the plenum. Fasteners, batteries, and major service points appear designed for horizontal access, helping streamline both assembly and aftermarket service operations.
NVH Materials and Structural Adaptations
Tesla listened to feedback from earlier models like the Model 3 and Highland—and it shows. The teardown highlights several NVH improvements, including PET fiber dampers and synthetic linings. Tesla likely heat-staked these materials onto wheel liners and surrounding surfaces.
This strategy helps insulate cabin noise more effectively. That’s crucial for a vehicle aiming to balance off-road toughness with luxury comfort. By addressing NVH early, Tesla boosts both performance and customer satisfaction.
The brake reservoir, possibly along with the master cylinder, is also mounted to the structural casting. This integration reduces complexity and weight while tightening tolerances around the 12V lithium-ion battery, which Tesla appears to have repositioned for optimized flow and serviceability.
Exterior Structural Elements and Exoskeleton Implications
One of the more visually striking aspects of the teardown is the front-end structure. While Tesla markets the Cybertruck as having an “exoskeleton,” the teardown reveals a hybridized approach: stamped aluminum brackets and what appears to be a glass-filled nylon intrusion beam (likely 50% fill) over-molded onto steel.
This beam appears to serve both crash and closure management roles. A closer look at the ribbing and over-mold marks suggests clever use of injection-molded plastics with steel reinforcement—an unusual but effective design strategy in the front-end module.
There’s also speculation about a possible radar unit returning, based on a small “window” at the vehicle’s nose. If true, this would mark a departure from Tesla’s recent camera-only strategies.
Aerodynamics and Movable Fascia Components
In the lower front fascia, the teardown team spotted a potential air dam or movable valence. This component, possibly retractable like those found in F-150 and RAM full-size trucks, would serve to reduce drag at highway speeds and retract during off-road use. It shows that Tesla is not compromising on efficiency despite the truck’s brutalist exterior.
The active grille shutters are also likely hidden behind the fascia, suggesting Tesla has kept aerodynamic elements concealed to maintain the Cybertruck’s durability-focused outer shell.
Interior: Minimalism for Margin
The Cybertruck’s interior follows a clear strategy: radical minimalism with maximum margin benefit. The yoke-style steering wheel, induction phone chargers, and perforated ventilated seats support a premium experience. Yet the flat, planar surfaces, single-piece panels, and low-complexity IP design mean less tooling, fewer parts, and lower assembly costs.
There are no stalks—Tesla has embedded turn signals and drive selectors directly into the thumb controls, echoing the Model S Plaid layout. The center horn returns, a nod to user ergonomics.
Also noteworthy: visibility design. The quarter glass was added not for style but to counter the massive blind spots caused by the Cybertruck’s extreme pillar angles. Tesla clearly modeled this vehicle with 360-degree obscuration in mind—balancing form with function under regulatory and safety pressure.
Roof Geometry and Headliner Observations
At the rear, teardown observations hint that Tesla may be using injection-molded headliner elements instead of traditional thermoformed cloth parts, especially given the sharp angular geometry of the roofline. This technique, already seen in the Model Y, would further Tesla’s goal of simplifying production while enabling unusual form factors.
Split-line indicators, acoustic grills, and likely use of faux suede or Alcantara add a touch of refinement while sticking to cost-effective materials.
Takeaways for EV Engineers and Investors
This Cybertruck dual motor teardown highlights Tesla’s maturing design philosophy:
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High integration: Components serve multiple roles—mounts, enclosures, structural links.
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Lean engineering: Reduced brackets, fewer part numbers, smarter fastening.
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Service and manufacturing accessibility: Parts oriented for maintenance without sacrificing automation.
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NVH improvements: Material science meets practical damping.
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Cost consciousness meets branding: Minimalist design delivers both thematic consistency and margin.
Tesla is demonstrating that the Cybertruck isn’t just a radical design statement—it’s a proving ground for manufacturing and engineering evolution that could ripple across its entire vehicle lineup.
Ready to Go Deeper?
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