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Tesla’s long-awaited Cybertruck has ignited debate across the automotive world, and now that more engineering details are emerging, Munro & Associates offers a first look into the structural choices behind the futuristic EV. This breakdown dives deep into Cybertruck’s structural design — from gigacastings and exoskeleton hopes to thermal system packaging and battery integration. For engineers, EV enthusiasts, and investors, these insights provide a grounded technical perspective on what Tesla is doing differently — and why it matters.
Reframing the Exoskeleton Vision
When Elon Musk first unveiled the Cybertruck, one of the boldest claims was its use of an exoskeleton rather than a traditional body-on-frame or unibody design. In theory, this would mean the outer stainless-steel skin would carry much of the vehicle’s structural load.
However, the teardown analysis reveals a more conventional approach. The vehicle includes a body-in-white style inner skeleton, complete with boron steel A and B pillars for crashworthiness. These components strongly resemble the high-strength frameworks seen in modern unibody vehicles like the Model Y. While the stainless-steel exterior will still provide added rigidity, the notion of a pure exoskeleton has taken a back seat — likely due to safety testing realities such as FMVSS 206 and the small overlap rigid barrier (SORB) tests.
Gigacastings and Load Path Innovation
Cybertruck continues Tesla’s trend toward massive die-cast components. The front of the vehicle features a single large casting that integrates the wheel wells and crush zones, providing rigidity and simplifying assembly. At the rear, Munro observed a dual casting configuration — large castings on either side that form a cross-car structure. These castings replace traditional multi-part welded assemblies, reducing part count, welding time, and weight.
The design shows attention to crash energy management, with crush cans and reinforced members to handle SORB loads. The team also noted that structural load paths from the C-pillar into the shock towers suggest Tesla intends for this design to handle significant forces during off-road driving or collision events.
Powertrain Mounting and Subframe Mystery
A mysterious casting seen in photos near the front of the vehicle puzzled the Munro team. It could be a structural element under the frunk, possibly used to mount the front powertrain — similar to what Tesla does with the Model 3 and Model Y. Its robust bolt pattern and mounting provisions suggest it could bear significant loads, potentially making it a dual-purpose component for structural reinforcement and drivetrain support.
If true, this would reinforce Tesla’s trend of using gigacastings not just for body structure but also to support suspension and powertrain assemblies — saving weight and increasing modularity.
A Rethink of Thermal and Electrical Packaging
The Cybertruck’s thermal system borrows elements from other Tesla vehicles, including rubber-isolated high-voltage AC compressor lines. However, it also introduces variations — likely due to the vehicle’s larger size and expected heavy-duty cycle. Visible elements suggest multiple chillers or liquid-cooled condensers, possibly hinting at more sophisticated cooling for battery and drivetrain systems.
Notably, the thermal configuration doesn’t mirror the Model 3, Y, or S. These variations signal that Tesla is adapting its proven systems for the Cybertruck’s specific needs — whether that’s towing, off-roading, or fast charging.
The Battery Pack: Cybercell and Structural Goals
Tesla is expected to equip the Cybertruck with a structural battery pack built around its 4680 cells. These cylindrical cells, manufactured at Giga Texas, enable Tesla’s vision of merging the battery with the vehicle’s structure, eliminating traditional crossmembers and lowering part count.
While production challenges persist — only 10 million 4680 cells had been made at the Texas plant by June 2024 — Munro speculates that Tesla is ramping up. The Cybertruck’s pack, dubbed the “Cybercell,” could feature advanced chemistries or a dry anode process, both aimed at boosting energy density.
The estimated pack size is around 1600 to 2000 cells, roughly double that of a Model Y, placing total capacity potentially between 120 and 150 kWh. This should deliver range estimates of 300–350 miles, assuming Tesla meets its weight and efficiency targets.
Manufacturing Considerations and Interior Assembly
Tesla’s manufacturing approach continues to emphasize simplification and modularity. The Cybertruck appears designed for bottom-up assembly of interior components — including seats, carpets, and wiring harnesses — a tactic Tesla pioneered with the Model Y.
This allows for fewer workstations along the main assembly line, lowering labor costs and floor space needs — key advantages when scaling production. Expect Tesla to deploy this strategy at Giga Texas in Cybertruck builds to maximize throughput.
Mass and Market Positioning
Despite early targets of a sub-three-ton vehicle, the Cybertruck now appears headed for a curb weight of 6800 pounds — over the 6000-pound threshold required for U.S. tax incentives. This places it between the Rivian R1T (~7000 lbs) and the Hummer EV (~9000 lbs), but with a unibody casting approach that avoids the complexity and inefficiency of body-on-frame layouts.
Sandy Munro and his team don’t view the Cybertruck as a direct competitor to the Ford F-150 Lightning or Rivian. Instead, they see it occupying its own niche: the adventure-oriented EV lifestyle buyer. While the F-150 Lightning appeals to contractors and tradespeople, and the Rivian to outdoor enthusiasts with gear-heavy needs, the Cybertruck aims to serve Tesla loyalists looking for ruggedness, utility, and style — with enough range and payload to make it practical.
Frunk Volume and Design Constraints
With a cab-forward design and a short front overhang, the Cybertruck’s frunk will offer less depth than those in the F-150 or Silverado EV. Still, its wide layout may accommodate two sets of golf clubs — stacked — and will likely be large enough for camping gear or emergency supplies. The frunk remains a Tesla staple, and even in this large truck format, it hasn’t been abandoned.
Final Thoughts: Not the Exoskeleton We Were Promised — But Still Revolutionary
While the Cybertruck has evolved away from Elon Musk’s exoskeleton dream, it remains a bold and groundbreaking vehicle. The structural rigidity, innovative gigacastings, integrated battery pack, and bottom-up assembly mark it as a serious step forward in EV manufacturing.
It’s not just about looking different — though the Cybertruck certainly does — it’s about building differently. Tesla’s commitment to eliminating inefficiencies, improving crash safety, and integrating battery technology directly into the vehicle frame shows that they’re still thinking far ahead of legacy OEMs.
For engineers and investors watching Tesla’s next moves, the Cybertruck isn’t just a truck — it’s a case study in how to rethink vehicle architecture from first principles.
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