Tesla Cybertruck Engineer Reveals New Changes in ‘Constantly Evolving’ Pickup
Lead Engineer Wes Morrill highlights a switch from aluminum to self-reinforcing polypropylene for the underbody aero shield.
Tesla Cybertruck Lead Engineer Wes Morrill disclosed that the company has implemented several modifications to the all-electric pickup, describing the vehicle as a "living thing, constantly evolving and improving."
What Happened
Morrill revealed that Tesla has made ongoing adjustments to the Cybertruck to enhance cost, reliability, serviceability, and manufacturability. While some changes remain undisclosed, a notable update involves the replacement of the underbody aero shield. The component, previously made of aluminum, now utilizes a self-reinforcing polypropylene material. According to Morrill, this new material is stretched into fibers and laminated into form, resulting in a part that is significantly lighter, more durable, and cheaper to manufacture than its aluminum predecessor.
Why It Matters
The material switch has enabled improvements in the Cybertruck’s geometry, specifically around bolts and edges, which has contributed to better durability and reduced drag. This approach highlights Tesla’s manufacturing philosophy, which diverges from traditional automotive cycles. Unlike other manufacturers that wait for new model years to implement sweeping changes, Tesla introduces updates fluidly as they become available. Consequently, Tesla vehicles are often identified by "generation" or "era"—such as "Juniper" for the Model Y or "Highland" for the Model 3—rather than by specific model years.
The Bottom Line
Tesla continues to refine the Cybertruck at Gigafactory Texas through iterative engineering improvements, prioritizing immediate enhancements over waiting for annual model updates.
