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In a recent teardown review by engineers at Munro, the Tesla Cybertruck’s suspension system underwent a detailed and technical deep dive. Using teardown comparisons with rival EV trucks like the Rivian R1T and Ford F-150 Lightning, this analysis illuminates how Tesla’s engineering decisions—especially in materials, geometry, and integration—define the Cybertruck’s ride characteristics. This Cybertruck suspension analysis sheds light on Tesla’s lean design strategies, offering expert insight into where performance, cost, and manufacturing efficiencies intersect in modern electric vehicle architecture.
The Front Suspension: Steel, Geometry, and Gigacasting Integration
Tesla’s front suspension setup on the Cybertruck employs a short long arm design. This layout balances durability with packaging efficiency. Of particular note is the upper control arm, constructed as a welded steel piece. While the steel clamshell design involves some compromises in material integrity due to weld zones, it presents substantial savings in tooling and capital investment—true to Tesla’s philosophy of minimizing cost while maintaining acceptable performance.
Compared to a more elegant Acura MDX execution (which presses bushings into the control arm without welding), the Cybertruck’s approach offers manufacturing simplicity. Tesla’s method enables nesting flexibility in the stamping process, potentially reducing material waste while maintaining structural control over camber and motion ratios.
The gooseneck knuckle is unusually tall—one of the tallest seen by Munro’s teardown team. This design, while unusual among trucks, allows for tight packaging with the wheel and upper ball joint, aiding tire clearance and enabling robust wheel options without compromising the load path. The Rivian and F-150 take alternative approaches, emphasizing flat-machined bolt-in knuckles or reoriented top portions to accommodate larger tires. In contrast, Tesla seems to prioritize controlling the loads entering the vehicle by potentially constraining tire size.
Material Choices: Steel vs. Aluminum in Load-Bearing Applications
The Cybertruck employs forged aluminum for its lower front control arms—a choice dictated by the high-load requirements of that suspension position. Aluminum’s benefits are clear: lighter weight and sufficient strength. However, it comes with higher costs. For Tesla, this tradeoff appears justified at the front, where packaging is tight and the casting or forging process better suits the complex geometries required.
Meanwhile, steel dominates the rest of the control arms, especially in the rear. Stamped steel with local reinforcements offers an efficient, cost-effective solution, allowing Tesla to leverage smaller presses or nested parts for higher output per stroke. The integration of selective reinforcements—especially around upper ball joints—illustrates how Tesla balances material costs and rigidity with surgical precision.
Knuckles, Bearings, and CV Integration: A Structural Shift
Tesla’s front knuckle integrates a Gen 3 unit bearing but with a unique twist: instead of a traditional standalone bearing and seal assembly, the Cybertruck’s design combines the CV joint and bearing into a unified assembly. This reduces the number of seals, simplifies packaging, and lowers weight. Though slightly more complex to install and service, this innovation hints at future industry trends.
This level of integration first appeared on the Iconic EV platform and now reemerges in the Cybertruck—potentially signaling a new baseline for Tesla vehicles moving forward.
Front and Rear Cradle Architecture: Scaling Model 3 Learnings
The Cybertruck’s front cradle scales the architectural philosophy of the Model 3 and Model Y. Tesla loops a D-shaped cradle around the motor and braces it with stanchions to the mid-section of the gigacasting. Slip-plane brackets allow the structure to slide and absorb energy during a crash—an emerging Tesla signature.
In both front and rear, Tesla’s use of short-long-arm geometry promotes consistent handling. While the rear’s teardown was incomplete, it mirrors the front setup in key areas: forged aluminum knuckles, stamped steel control arms, and a cradle system that bolts directly to the body rather than relying on subassembly integration. This direct mounting strategy is rare but enhances rigidity and reduces part count.
Global Sourcing: Made in China, Mexico, and the USA
A key revelation from the teardown was Tesla’s diversified sourcing strategy. Rear cradles and control arms originate from Mexico, while large castings like the front and rear knuckles are made in China. US-sourced stampings still make up the bulk of structural components. Tesla appears to be optimizing costs by balancing proximity, logistics, and regulatory compliance (particularly under the USMCA guidelines), blending low-cost manufacturing zones with high-performance part demands.
Air Suspension: Simplicity Versus Complexity
The Cybertruck’s air suspension draws both praise and scrutiny. Unlike the Rivian R1T’s air-over-hydraulic system—which forgoes sway bars in favor of highly adaptive, corner-isolated dampers—the Cybertruck leans on simpler, cost-effective air ride technology.
Tesla’s air pump and reservoir are smartly positioned above the rear gigacasting, sandwiched between it and the bed for added protection. This thoughtful packaging contrasts with the Rivian’s more exposed rear components, vulnerable to rock damage in off-road scenarios.
However, integration opportunities were missed. Rather than fusing the air reservoir into the casting or bed, Tesla opted for a more traditional standalone unit. While this decision likely improved development speed, it fell short of the brand’s usual integration ambitions.
Air Ride vs. Electromagnetic Dampers: A Strategic Tradeoff
Air ride delivers practical advantages for trucks: ride height variability, better comfort under heavy load, and modest manufacturing costs. But it’s not performance-oriented. You won’t find air ride on supercars or track weapons like the Porsche 911 or Shelby Mustangs. Those vehicles favor electromagnetic dampers—precisely tuned, clean-room-assembled, and IP-heavy systems that command a premium.
Tesla’s use of air suspension on the Cybertruck speaks to its comfort-focused priorities. The platform targets utility users, not canyon carvers. And for that market, air ride checks the right boxes—offering comfort, adjustability, and a competitive cost structure.
Final Takeaways: Lean Choices for a Bold Platform
From the use of stamped steel and forged aluminum to the hybrid cradle strategy and global part sourcing, the Cybertruck exemplifies Tesla’s commitment to lean manufacturing. Every design choice seems calculated to balance cost, performance, packaging, and serviceability.
The suspension system—air ride, integrated bearings, tall knuckles, and welded control arms—offers an elegant if unconventional blend of utility and innovation. Compared to rivals like Rivian, the Cybertruck feels more industrial, more grounded in cost-efficiency than over-the-top engineering.
Yet that’s its strength. Tesla’s strategy sacrifices some flair in favor of scale, speed, and service practicality. It’s a platform made to endure—on the road, off the road, and in the factory.
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