Cybertruck Tonneau Cover: Function, Cost, and Design

The Tesla Cybertruck is nothing if not bold. And that design philosophy extends all the way to the bed—specifically its unique retractable tonneau cover. In this teardown discussion from the engineering team at Munro & Associates, we explore the engineering trade-offs, materials, and functionality behind Tesla’s tonneau design. Compared to Rivian’s simpler solution, the Cybertruck’s system prioritizes structural rigidity, durability, and style. But those priorities come at a cost.

Engineering a Rollable Vault System

Unlike traditional truck bed covers, Tesla opted for a roll-up method that resembles a tank tread system more than an aftermarket cap. The Cybertruck’s tonneau cover is made up of 29 individual single-cell extruded slats. Each segment is precision-crafted to allow the entire unit to bend and roll into a storage compartment at the front of the truck bed.

In contrast, the Rivian R1T uses a cartridge-style approach, which involves fewer but thicker three-cell extrusions. While this makes the Rivian system compact and easier to package, it limits its mechanical robustness and may contribute to early wear—something Munro’s teardown team observed firsthand.

Material Choice and Mechanical Complexity

To reduce friction and extend lifecycle durability, Tesla engineers selected Polyoxymethylene (POM) plastic—commonly used in fuel systems for its high lubricity and chemical resistance—for critical injection-molded bearing parts. These parts form the drive interfaces that roll the slats in and out.

What stands out in the Cybertruck system is the use of multiple common parts and symmetrical designs. Despite its complexity, Tesla has managed to reuse components like crossbars, seals, and connectors throughout the assembly. The consistent part design simplifies sourcing and potentially lowers costs over high-volume production.

The entire rolling mechanism is supported by two large multi-piece injection molded end caps that resemble drive wheels on a tank. Each end cap includes bearings, rollers, and a dog-bone style connector. These are crucial for maintaining consistent force distribution along the length of the tonneau system.

Motor and Drive Comparison: Cybertruck vs. Rivian

One of the most noticeable differences between Tesla and Rivian’s systems is the size and strength of the motor assemblies. Tesla’s motor and gearbox setup is massive—estimated to be at least four times the size of Rivian’s. This is likely due to the need for greater torque and control over the Cybertruck’s longer and more complex cover system, which must travel further and resist more potential load.

In Rivian’s system, the drive train is much smaller, relying on a single motor with a relatively compliant rod. This leads to slack and system “wind-up,” which can degrade performance over time. Tesla counters this with deep sprockets and a robust engagement track, ensuring minimal slippage and consistent operation—even under load or in harsh conditions.

The Role of Design in Functionality

One of the more unique decisions Tesla made was to fully integrate the tonneau system into the vehicle’s design envelope. The bed cover isn’t just a utility—it’s a visual and aerodynamic extension of the Cybertruck’s unibody sail panels. This integration contributes to the truck’s overall silhouette and drag coefficient but introduces limitations.

Because the system reaches up toward the roofline, the design demands a longer and more powerful drive system than what you’d find on a conventional pickup. Additionally, the shallow rear window (Z-height) creates a significant visibility challenge when the cover is closed—something critics have noted as a major trade-off in Tesla’s pursuit of styling.

Still, for owners prioritizing lockable, hard-shell security and all-weather protection, the trade-offs may be worth it. The tonneau cover can support up to 300 pounds and appears capable of resisting environmental hazards like snow or ice, thanks to its powerful drive train and dirt-sweeping brush seals.

Assembly and Manufacturing Implications

From a manufacturing perspective, the Cybertruck tonneau cover is a study in complexity. While the total part count is high, the consistent use of extrusions and shared mold designs reflects lean manufacturing principles. It’s likely that Tesla will rely on partially automated assembly processes—particularly for the insertion and swaging of overmolded components.

The team from Munro points out that despite the high number of parts, many are laser-etched with shared IDs, implying scalable production intent. However, even with this level of standardization, the Cybertruck’s tonneau remains a more intricate system than typical OEM or aftermarket solutions.

This complexity suggests higher upfront production costs, but potentially lower per-unit costs as volumes scale and Tesla dials in its manufacturing flow.

Cost vs. Function: A Balancing Act

Ultimately, Tesla made a conscious trade: prioritize styling, durability, and integration over simplicity and low cost. The Rivian R1T’s system is compact, efficient, and less prone to high tooling expenses—but it has struggled with long-term reliability. Tesla’s approach is more robust and better aligned with the Cybertruck’s brand identity as a futuristic, high-performance utility vehicle.

That said, the Cybertruck tonneau system does come with compromises. The limited rearward visibility, the physical bulk of the system, and the inherent complexity may deter users looking for a more utility-focused truck. Accessories like salt spreaders or racks will likely require bespoke mounts, limiting off-the-shelf compatibility.

Yet, it’s these very compromises that make the Cybertruck tonneau unique in the EV truck space. It’s not just a bed cover—it’s part of the vehicle’s performance envelope and visual language.

Cybertruck Tonneau Cover Analysis Takeaways

For those in the EV and automotive engineering fields, the Cybertruck tonneau cover offers several key lessons:

• Design Integration Impacts Everything: Styling, performance, and packaging are tightly linked. Aesthetic goals must be balanced with cost and utility.
• Material Selection Matters: Using higher-end materials like POM adds durability but also cost. It must be justified by lifecycle performance.
• Complexity Can Be Scaled: Tesla’s use of common parts and extrusions shows that complexity doesn’t always mean inefficiency—if managed properly.
• Visibility and Usability Still Count: Designers should consider how integrated systems affect real-world use, from visibility to cargo access and serviceability.

Get More From Munro

For more teardown insights, cost breakdowns, and EV manufacturing analysis, explore Munro Live’s library of expert videos and blog posts. Want to know how your vehicle’s system compares? Reach out to Munro & Associates for a detailed design and cost benchmarking consultation.