Skip to content 
Tesla’s Cybertruck has already captivated the world with its bold design, but engineers and enthusiasts alike have been eager for deeper insights into its underlying mechanics. The Munro team recently took an expert first look at Tesla Cybertruck’s suspension system and reviewed it based on roadside photos of a prototype — offering valuable clues about the truck’s engineering, material choices, and crash safety strategies.
Let’s dive into the details of this preliminary analysis.
Front Suspension: Cast Aluminum for Strength and Safety
Initial observations of the Cybertruck’s front suspension reveal a relatively conventional setup at first glance. The front casting appears to be either a low-pressure permanent mold die-cast or a sand-cast aluminum component. Cross-hatching on the surface aids in cooling and releasing the casting from the mold.
A closer look highlights that the outer tie rods connect to a billet-machined steel prototype part. This is a clear marker that the vehicle spotted is indeed a prototype. Machining parts directly from bar stock allows Tesla to avoid full tooling costs during the prototyping phase, making quick iterations possible without mass production investments.
The use of aluminum at the front is not just about weight savings. It supports Tesla’s strategy to improve safety in Small Overlap Rigid Barrier (SORB) crash scenarios. Aluminum is chosen because it fractures under severe loads, allowing the wheel assembly to peel away from the passenger cabin during a collision. This prevents intrusion into the occupant space, a critical factor in maintaining crashworthiness.
Carbon Fiber Protection: Strategic and Surprising
Interestingly, we noted the presence of carbon fiber shielding at the leading edge of the battery pack, bolstered by steel structural components above it. While a costly choice, depending on production volume and layup techniques, carbon fiber can offer exceptional puncture resistance, stiffness, and lightweight benefits. In the Cybertruck’s case, this likely aids off-road protection and reinforces durability without adding excessive mass.
Given Tesla’s focus on manufacturing efficiency, it’s plausible that Tesla is using a Sheet Molding Compound (SMC) process to produce these carbon fiber components at scale, balancing cost with performance.
Rear Suspension: Steel for Cost and Weight Optimization
Moving to the rear, the suspension architecture changes notably. Instead of aluminum castings, Tesla opts for stamped steel clamshell structures welded together. This choice is strategic.
Stamped steel systems can often match or even outperform aluminum counterparts in weight, while dramatically reducing manufacturing costs. For an application like the rear suspension — where crash energy absorption needs differ from the front — stamped steel provides a robust, economical solution.
Moreover, the team discovered clear evidence of four-wheel steering. A ball joint on the rear knuckle, coupled with steering rack linkage hints, confirms Tesla’s commitment to providing enhanced maneuverability, particularly beneficial for such a large vehicle. Tight turning radii will be a hallmark of the Cybertruck’s handling, and four-wheel steering plays a key role in delivering that capability.
Air Suspension: Expected but Well-Executed
Like many modern trucks and premium EVs, the Cybertruck features air suspension technology. Air suspension brings adaptive ride height, load leveling for towing, and improved off-road capability. Tesla’s system includes a protective shield around the airbag, a vital addition for off-road use where punctures could otherwise quickly disable the vehicle.
The system enables features such as “kneeling” for easier entry and exit, ride height adjustments for highway efficiency or rough terrain, and automatic leveling when hauling loads. In short, it aligns with industry expectations but demonstrates thoughtful execution and packaging.
One area of concern noted by Munro involved high-voltage cabling. Visible orange cables run underneath the vehicle near air suspension components. Typically, OEMs heavily shield such critical systems, especially for off-road vehicles, to prevent damage from debris. It remains unclear whether this prototype simply lacked full shielding, or if Tesla plans additional protective measures for production models.
Rear Steering Components: Precision Matters
Our review of the suspension system photos also revealed close-ups of the Cybertruck’s rear tie rods. Designed with left- and right-hand threads, the tie rods allow fine-tuned camber and toe adjustments during suspension alignment. Jam nuts lock the desired settings into place.
This robust setup supports the Cybertruck’s four-wheel steering functionality, ensuring precise control under various driving conditions. It hints at Tesla’s serious commitment to delivering a high-performing, highly controllable electric pickup truck — not just a futuristic body shape.
Materials Strategy: Balancing Innovation and Cost
Tesla’s material choices in the Cybertruck reflect a nuanced understanding of automotive engineering tradeoffs. Aluminum castings in the front provide critical crash safety advantages and reduce unsprung mass, improving ride and handling. Carbon fiber shields demonstrate a focus on puncture resistance and structural integrity around the vulnerable battery pack. Meanwhile, stamped steel in the rear suspension minimizes cost without sacrificing performance.
This blend of materials follows the broader industry trend toward lean design and feature integration, hallmarks of modern lean manufacturing philosophies. Tesla continues to refine its “gigacasting” approach, extending it beyond body structures and into suspension strategies where appropriate.
Prototype Status: Expect Changes Before Final Production
It’s important to note that this Cybertruck appears to be an early prototype. Machined tie rods, visible cabling, and missing shielding all suggest that production-intent refinements may still be underway. As with previous Tesla vehicles, final production versions may feature additional brackets, covers, or material changes based on crash testing, regulatory compliance, and manufacturing optimizations.
Regardless, the insights gleaned from this first look reveal a strong foundation: lightweight materials, robust off-road protection, advanced four-wheel steering, and intelligent suspension engineering.
Review Takeaways for the Cybertruck Suspension System
- Aluminum Front Suspension: Optimized for crash safety (SORB compliance) and weight reduction.
- Stamped Steel Rear Suspension: Smart cost-weight compromise enhancing rear axle durability.
- Carbon Fiber Battery Shield: Advanced puncture resistance for off-road survivability.
- Four-Wheel Steering: Tight turning radius and improved low-speed maneuverability.
- Air Suspension: Adaptive ride quality, trail-ready features, and efficient load management.
- Visible Gigacastings: Evidence of Tesla’s evolving manufacturing strategy applied beyond the body-in-white.
Conclusion
The Cybertruck’s suspension design represents Tesla’s pragmatic approach to innovation — blending new technologies where they matter most, while controlling costs with proven engineering methods. This early look reinforces that Tesla isn’t just thinking about bold aesthetics; they are laying the groundwork for durable, high-performance electric trucks capable of meeting real-world demands.
Stay tuned to Munro & Associates for future teardowns and engineering deep dives. If you want expert insights on lean design, EV manufacturing breakthroughs, and detailed cost analysis, make sure to follow Munro’s ongoing coverage.