FYI: Tesla’s Cybertruck development highlights groundbreaking integration and optimization, unveiling unique design philosophies that push automotive innovations beyond conventional boundaries.
Tesla Cybertruck Engineer Discusses Deep Integration and Vehicle Development
Tesla Cybertruck Lead Engineer Wes Morrill recently provided in-depth insights into the company’s distinctive approach to vehicle design on social media platform X. Morrill’s commentary offers a glimpse into the meticulous attention to detail that characterizes Tesla’s disruptive automotive engineering.
Evolution of Tesla’s Design Philosophy
The unmistakable design of the Tesla Cybertruck is a testament to advanced automotive engineering, but achieving such a level of sophistication took time. Morrill recounted that during Tesla’s formative years, different teams with shared goals were responsible for vehicle design. While this collaborative approach yielded high-quality cars, it did not result in optimal designs.
"In the early days, Tesla’s battery team and the vehicle structures team worked separately. The structures team designed the vehicle body to meet requirements of strength, crashworthiness, and torsional stiffness, while the battery team ensured the battery was self-contained and durable. Each team met their goals independently, but the final product was a ‘box in a box’—efficient yet not optimized," Morrill explained.
Learning from Experience
Tesla’s journey toward optimization involved significant learning and adaptation. The company’s realization led to groundbreaking innovations like the structural battery pack, a feature now being replicated by other electric car makers. However, Morrill emphasized that such advancements often require substantial organizational changes and a collective drive to create the best product, free from ego.
"Before the next product was designed, responsibilities for battery structures were handed over to the vehicle structures team. This resulted in the development of the structural battery, integral to the vehicle’s body and crash structure, eliminating redundancy and increasing efficiency. This product also achieved one of the highest crash safety ratings at the time," noted Morrill.
Breaking Down Organizational Barriers
Morrill highlighted that even minor technical decisions can benefit from a mindset focused on optimization and open to improvement. This collaborative approach has produced several ingenious design elements in the Cybertruck, such as:
- Chassis air suspension: Used to pressurize the battery pack to prevent water ingress.
- Subwoofer design: Utilizes the air volume of the body side to avoid larger enclosures.
- Centralized zonal vehicle controllers: More efficient than numerous small distributed controllers.
- Crash intrusion beams in doors: Exterior surfaces double as crash intrusion beams.
"The motivation and excitement to work across boundaries and actively challenge organizational constraints are among the many reasons I love working at Tesla," Morrill shared.
Conclusion
Tesla’s journey of integration and optimization underscores the importance of collaboration and continuous improvement in vehicle design. By aligning teams and fostering an environment open to innovation, Tesla has been able to create some of the most efficient and safe vehicles on the market.
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William Kouch, Editor, Automotive.fyi
