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Tesla’s Cybertruck continues to spark headlines for its radical design. But the real engineering story of the Cybertruck might be what lies beneath—the underbody. In a recent teardown, Munro & Associates’ expert team dove into the truck’s suspension layout, structural strategy, and material selection—revealing a blend of bold innovation and calculated trade-offs.
This engineering deep-dive into the Cybertruck’s underbody isn’t just a curiosity for EV fans—it’s a roadmap for how Tesla is rewriting the playbook on lean design and manufacturing in electric vehicles.
1. Unconventional Protection: Thermoformed Shields and Aero Ducting
The teardown kicks off with a closer look at a curious feature: a plastic shield over the front suspension. Likely a thermoformed part, this component appears designed for aerodynamic advantage or debris deflection. Yet its placement raises eyebrows—it could trap mud during off-roading, suggesting Tesla still balances aesthetics and real-world performance.
Instead of clipping or snapping into place, this shield is fastened with bolts—raising potential concerns about cost and maintainability. The team notes Tesla may revisit this strategy as field data rolls in.
2. Suspension Choices: Forged, Stamped, and Smartly Simplified
Tesla deviates from convention with a single-stamped steel upper control arm. Most OEMs opt for multi-piece weldments or forged aluminum, especially on high-performance vehicles. But the Cybertruck’s SLA (Short-Long Arm) front suspension minimizes loads on the upper control arm, allowing this simplified design to thrive.
This strategic use of a stamped arm aligns with Tesla’s lean philosophy: fewer tools, no welding, and weight savings without compromising control. It’s a standout example of using finite element analysis (FEA) to eliminate overengineering.
3. Smart Integration: Load Paths and Crash Management
Tesla’s cradle geometry and tow hook provisions reflect thoughtful crash energy management. Rather than letting a crash disable structural elements, the Cybertruck’s cradle design channels energy in controlled ways. This includes provisions to allow components to shear off or move rearward during a collision.
A bolted-on aluminum insert at the front knuckle likely serves as a small overlap rigid barrier (SORB) countermeasure. This piece may help deflect or fracture the wheel to prevent intrusion into the cabin—an elegant solution balancing safety, performance, and repairability.
4. Electric Steer-By-Wire and Space Optimization
The Cybertruck places its electric power steering (EPS) rack ahead of the spindle—a move made possible by its steer-by-wire architecture. With no intermediate shaft connecting the driver to the steering mechanism, Tesla gains layout freedom, maximizing space for drivetrain and cooling components.
The underbody also reveals active grille shutters and a front-mounted pedestrian speaker, underscoring Tesla’s attention to safety and aero management even at low speeds.
5. NVH and Material Strategy: SonoSorb Pads and PET Layers
One highlight is Tesla’s use of SonoSorb sound-dampening pads, heat-staked from PET layers and strategically placed on the vehicle’s underside. Unlike conventional wheel liners that absorb moisture, these internal pads resist water saturation, preserving long-term noise, vibration, and harshness (NVH) performance.
It’s a small but telling example of Tesla’s meticulous attention to detail—a layered decision that balances cost, performance, and long-term durability.
6. Rear Axle and All-Wheel Steering Strategy
Moving rearward, the teardown uncovers a kingpin-style rear knuckle with components resembling a heavy-duty truck. Tesla likely repurposed front steering rack layouts to enable rear-wheel steering, granting Cybertruck tighter turning radii and improved off-road maneuverability.
Notably, the EPS system in the rear appears compact—more like a plunger-based setup than a full rack. This suggests modularity and cost savings, mirroring the Audi Q8’s engineering approach.
7. Stamping vs. Casting: Where Tesla Draws the Line
Tesla leans heavily into stamped aluminum for the battery pack’s underbody structure, a shift from the extrusions used in earlier models. Stamping lowers costs at high volumes and simplifies manufacturing.
The rear electronics bay, in contrast, is cast aluminum and cantilevered over the battery—a clear structural element, potentially stiffening the battery itself or reinforcing the body. This architectural departure hints at Tesla’s evolving design logic: cast where it counts, stamp where it saves.
8. World-Class Underbody Spot Welding and SPR Execution
Spot welds on the Cybertruck’s underbody show exceptional engineering precision—a sharp contrast to early Tesla builds. Our team praises their consistent execution, noting that Tesla now achieves clean, dimple-like welds even on dissimilar materials.
The use of Self-Piercing Rivets (SPRs) further demonstrates advanced joining techniques, especially where adhesives or RTV (Room-Temperature Vulcanizing) seals are in play. These methods reflect world-class material science and process control, especially for aluminum-steel interfaces.
9. Hidden Connectors and Modular Design Intent
Our teardown found multiple unused high- and low-voltage connectors tucked near the battery and rear hitch—likely placeholders for future features, optional upgrades, or assembly-line diagnostics. This modular design philosophy suggests Tesla is already thinking ahead to model variants or future accessories.
Whether for bed-integrated tools, rear winches, or extended charging options, these provisions reinforce Tesla’s readiness for over-the-air upgrades and accessory ecosystems.
Conclusion: Pushing the Cybertruck Envelope from Below
Tesla’s underbody architecture on the Cybertruck showcases a careful dance between innovation and pragmatism. From stamped control arms to integrated crash countermeasures and precise spot welding, every component reflects a larger mission: reduce cost, maintain strength, and push EV design forward.
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