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Tesla continues to redefine the EV landscape, and the new Cybertruck power conversion system—known as PCS2—is no exception. In a recent deep-dive with Munro & Associates and 3IS, we examined the robust new architecture found inside Tesla’s most rugged EV yet.
Not only do we explore the major engineering changes in the Cybertruck’s power electronics—from its shift to a 48-volt system to the implementation of redundant DC-DC converters and advanced bidirectional charging. We also give you a teardown-rich analysis packed with insights for automotive engineers, EV enthusiasts, and investors.
From 12V to 48V: A Leap in EV Architecture
One of the most significant shifts in the Cybertruck is its 48-volt electrical architecture. Previous Tesla vehicles operated on 12-16V systems with a single DC-DC converter. PCS2 replaces this setup with dual DC-DC converters, offering redundancy and failover capabilities. If one unit fails, the other seamlessly takes over—critical for steer-by-wire systems and other safety-sensitive features.
This dual design represents a major reliability boost, showcasing Tesla’s commitment to design for reliability (DFMEA).
Bidirectional Charging and Power Export
PCS2 doesn’t just bring power into the Cybertruck—it sends it back out. The bidirectional charging capability is a first for Tesla. Owners can now tap into the Cybertruck’s battery to power their home or tools, making the vehicle a true mobile energy source.
PCS2 delivers up to 400 amps through the DC fast charge port. This opens the door to a range of vehicle-to-home (V2H) or vehicle-to-load (V2L) applications without specialized hardware—particularly helpful on job sites or during outages.
Physical Evolution: Smaller, Lighter, Smarter
Visually and structurally, PCS2 is a massive departure from earlier Tesla onboard chargers. According to Munro’s teardown, the new unit is approximately 50% smaller and significantly lighter. This isn’t just a packaging win—it’s a cost and efficiency breakthrough.
The design eliminates bulky electrolytic capacitors and uses printed circuit board (PCB) inductors built directly into the board. These copper trace spirals become effective inductors when paired with solid ferrite cores, offering a lower profile, vibration-resistant, and cost-effective alternative to traditional wound coils.
This move shows a classic Munro tenet in action: lean design meets high function.
Redundant Circuits and Scalable Design
A closer look at the board reveals two carbon-copy DC-DC converter circuits—a clear sign of modular, scalable architecture. Tesla could choose to depopulate parts of this board for different trims or use the same board across multiple platforms, just as it does with propulsion inverters for different motors.
This approach maximizes economies of scale, reduces production complexity, and creates a flexible foundation for future product lines.
Thermal Management: Familiar Yet Refined
The thermal strategy in PCS2 remains similar to past Tesla hardware, using cold plates, perimeter seals, and thermal gap fillers. However, improved layouts and insulation reflect lessons learned in vibration and heat management—especially around component fixation.
For example, added RTV reinforcement on some components suggests Tesla has fine-tuned its approach to combat mechanical stress and long-term wear.
Exportable AC Power: More Than Just EV Charging
Tesla doesn’t stop at DC export. PCS2 supports 240V single-phase AC output, making it possible to run appliances, jobsite equipment, or even home circuits directly from the vehicle. The Cybertruck includes multiple 120V and 240V outlets—both in the truck bed and the cabin.
With power output possibly exceeding 10 kW, the Cybertruck turns into a powerful generator on wheels—again emphasizing its utility-focused mission.
Engineering Tools Behind the Teardown
Munro credits Intrepid Controls for providing Ethernet and analysis tools like the Rad Gigastar and Rad IO2, which proved critical in understanding PCS2’s functions. These tools enable deep insight into automotive Ethernet traffic and powertrain communications, making them invaluable for this level of analysis.
Final Thoughts: PCS2 and the Future of EV Platforms
Tesla’s PCS2 is more than just a power conversion unit—it’s the backbone of the Cybertruck’s modern architecture. With its shift to 48V, support for bidirectional charging, integrated AC output, and modular design, PCS2 points to Tesla’s next-generation EV strategy.
These innovations will likely scale across the company’s lineup. As Munro notes, features like steer-by-wire, exportable power, and 48V systems will soon become staples in other Tesla models—and possibly the broader EV market.
Want More Expert Teardown Insights?
The PCS2 is just one chapter in the Cybertruck story. Munro’s full report dives deeper into silicon identification, x-ray images of the PCB, thermal interface materials, and more. Stay ahead of the curve—download the full Cybertruck report from Munro & Associates today.