The Evolution of Tesla's Body Structure - Caresoft Teardown

[@grmmjhnsn2]

Mr. Woychowski is a pure delight to listen to. So well informed, articulate, and engaging.

[@ycnexu]

My gf noted he also has a very pleasant tone of voice / way of speaking.

[@Ryanstuff]

That hammer was from the original reveal demonstration of how tough the doors were

[@edwardsp1916]

Credit to the camera person, great filming. Interesting video, well presented too.

[@peteregan3862]

What a great partnership - Autoline and CareSoft. The Autoline audience learns much, CareSoft markets it skills to existing and potential customers.

[@DougWedel-wj2jl]

0:50 It’s cool hearing how many parts got deleted by using the gigacastings. I appreciated hearing the list of processes all these parts go through. There is one more point on this. Tesla makes the gigacastings themselves, vs all these parts in the old frame structure would have been built by suppliers. That affects cost, quality control, the ability to change the design as you go, etc.

[@DougWedel-wj2jl]

70 fewer parts less in the back, 360 fewer parts in the front. A lot of these parts would be in pairs, usually mirror image for left and right, right?

[@asimo3089]

Seeing comments about this frame being more expensive to repair. You don't repair frames. Any insurance company totals the car if your frame has been compromised. John and Terry, thank you!

[@aussie2uGA]

Thats true but wouldn't this mean any minor incident that you may get away with repairing on a traditional build now will total the Cybertruck? Seems like insurance premiums for this will soar.

[@GTO33]

But this car doesent have a frame, its a monococque, and the castings go all the way to the front so that just a tiny damage will total the car.

[@asimo3089]

​@@aussie2uGA Minor accidents don't touch your frame. Major accidents (with airbags) do.

[@ArthurZakaryan23]

My brother-in-law has owned his bodyshop for over 20 years now and deals with every major and lesser known insurance companies and these days they total cars for the smallest of damages so you can bet any most if not all frame damage would be deemed totaled by the insurance companies.

[@danharold3087]

According to WalletHub, 70-75% of totaled cars are eventually repaired. Having seen the CT I can envision that there are going to be a lot of CT's repaired with replacement body sides, casting, and skin harvested from totaled vehicles. No body work required. Whe have seen a few CT's where body panels are push in a bit. Looks like the non stainless backing the stainless provides crush to allow for this. A very interesting system.

[@scoobasteve69420]

i could listen to walter white talk about teslas all day

[@ArthurZakaryan23]

Right? I mean I can see how this could put 99% of people to sleep, super dry topic but something about the way Terry breaks things down is just super fascinating. I absolutely love these trips to Caresoft. Terry is like a automotive forensic investigator lol.

[@markplott4820]

MUNRO is better.

[@scoobasteve69420]

@@markplott4820 Munro rambles about himself too much. I like both though

[@Jasonfallen71]

@@markplott4820Sandy’s the uncle who always enjoys a few and Terry is more erudite and no-nonsense. Both are charming and brilliant. I’m like “this is the part of How It’s Made I never really saw, a deep dive into the brilliance of each particular engineering solution. And the mundane too. But we’re here for the brilliance

[@arondaniel]

You're Goddamn Right.

[@garyrooksby]

Terry is fantastic. I'll be back for all future videos featuring him. I've already watched your previous vids with him.

[@TylerBrungardt]

Guy is very good at explaining things. Love how he takes his time and clearly understands everything he is talking about. Makes it very easy to sit and learn.

[@jorgecintron9674]

This was awesome!! I was glued to the tv. I love the Johnny Cash look too! This guy needs to be driving a blacked out Cybertruck! Do it!!

[@brianstanfill2114]

This was a great video and the explanations were really helpful. I learned things today. Thanks.

[@alfredogonzalez1280]

Great video ! The technology evolution within Tesla is amazing. They use concurrent design to account for all functional and manufacturing requirements from the start of the project.

[@TheJazzper1970]

Excellent video, thanks.

[@jaydeister9305]

Thank you for another great presentation on Tesla from Autoline Network and Caresoft!

[@8ballphilc]

Such a pleasure to listen to someone who knows what they are talking about! Great job Terry and props to the cameraman!

[@DougWedel-wj2jl]

15:25 I remember when I was a kid I rode in the back of a pickup truck and placed my fingers between the cargo box and the cabin. The cab, box and frame were separate pieces that flexed! And they started to flex on my fingers! Building all as one structure is a lot more rigid.

[@mibars]

That's exactly how trucks are designed, body is actually mounted through rubber bushing on a frame to separate it from both the box and the frame itself.

[@jonlivingstone]

What a great analysis!

[@slartybartfarst9737]

Design out cost and complexity. Thank you Mr Woychowski. And let me say now ITS BLOODY OBVIOUS! 44 years engineering in big auto world wide, I say engineering 50% of it was designing. Any engineer worth his / her salt shall follow that mantra or get the hell out. Ive seen 100s of "engineers" over the years add and add and add to solve problems, useless, its often interdepartmental politics to blame and/or lack of vision. In addition it should look right, and last it should be fun if you dont understand what I mean your in the wrong job. Thank you John these tear downs are so interesting.

[@eugeniustheodidactus8890]

Easily one of my favorite Tesla engineering videos! The engineering progression over only a few years is astonishing.

[@alanmay7929]

its clearly not and it makes an inferior product at the finish. nothing will ever beat body on frame vehicle.

[@whattheschmidt]

@@alanmay7929 You completely miss why John and Terry are impressed by this and why it matters. You only come off as hating Tesla for no reason. I'm not going to explain it because you are probably a lost cause.

[@sergiomessina2037]

Such a quantum leap from your Thursday's show that features Detroit insider dinosaurs hoping for the status quo to continue for the tradition auto market. Great video! Hope to see more.

[@chrisstavro4698]

I saw that BIW in person at WCX. It's stunning to see how big that rear gigacasting is in person. It uses a lot of great materials/manufacturing technology that translates to ICE vehicles perfectly.

[@markplott4820]

ICE vehicles , are a DEAD end. same with Hybrids, FCEV, and CNG.

[@kqschwarz]

Fantastic insights. THANK YOU.

[@eugeniustheodidactus8890]

As I recall, the curvature in the front gigacasting ribs was designed to decrease flow time for the molten aluminum, thus enabling Tesla to utilize the smaller gigapress vs the 8 ton that IDRA had specified for the front casting. Tesla designs OUT so much cost, it is astonishing.

[@alanmay7929]

nope

[@eugeniustheodidactus8890]

@@alanmay7929 you don't know jack shit

[@JustWasted3HoursHere]

We may not all like Tesla and I certainly have my issues with them and its leader, but there is no doubt that they have turned the automotive industry on its ear and kicked it in the pants in many ways, including in how the car is physically put together as efficiently as possible. Legacy manufacturers were cruising along for decades with the same build mentality because it worked and they knew how to do it very well, but now they are seeing that there are always ways to improve efficiency in construction and are slowly making those changes themselves. Making huge changes in how cars are put together is very expensive at the beginning but the benefits are gained in a pretty short amount of time.

[@AuralioCabal]

Unfortunately for Legacy Auto the Chinese are moving almost in Sync or following Tesla as fast as they can,at least two automakers there already have Gigacasts cars in production, we don't even know who of Legacy Auto ave ordered their Giga presses!

[@markplott4820]

what Laptop ?

[@kazedcat]

I don't understand this liking a company. All companies want your money so you just need to judge if they have a good product.

[@sergiomessina2037]

The question here is, will the legacy OEMs still have market share by the time the new costs amortize?

[@mikes-wv3em]

@@AuralioCabal most crap is chinese cast pot metal

[@deltajohnny]

Awesome presentation! I could hear him all day 👏👏👏

[@RobKardazan]

Compare that breakdown to a mega off roader truck like a Land Rover, Jeep or Bronco and clearly Tesla is achieving an engineering masterpiece on a scale that will allow more cost savings with strength enhancements. Exceptional engineering. Benchmark.

[@GRP55-fz2hv]

If only they could pass the savings to the customer

[@captiannemo1587]

Indeed, they want as much margin as possible.

[@CasperCastrol-rq8ed]

Wow..! what a brilliant insight. I am so much delighted by this video. Thank you so much for this video.

[@alex135789]

As always very impressed. Much appreciated. Thank you.

[@flattire707]

They just get better and better. Love my Model 3LR/FSD.

[@DougWedel-wj2jl]

At 3:02 you show a crush can that looks like it’s made separately from the front the gigacasting. Build it as part of the gigacasting but design it so when it crushes you cut it off from the rest of the GC and then have a new part that sleeves on to the trimmed GC. You eliminate this pair of crush cans but you don’t need to sacrifice the whole GC in a minor crash.

[@TheDoggydogworld]

That's the 2022 Model Y at 3:02. CT doesn't have the crush cans. It has a "corrugated" area in the casting designed to "accordian" in a crash. Start watching at 6:00 for a comparison. Not clear if the corrugated area can be cut out and replaced or if a low speed crash simply totals the CT.

[@markadams7799]

Excellent. Thanks for making this video

[@zilogfan]

More of this content, more detail Please.

[@ivankuljis1780]

Crikey, that was some explanation of _GENIUS STUFF_ More Please!

[@kb8570]

They need to teach this in all American schools. Amazing!

[@georgedoolittle7574]

I think structural rigidity, safety and longevity vastly improved as well besides dramatic loss in need for various parts both for assembly and any post fender bender issues. Very impressed by this and the need for safety gloves now too/as well. Be interested to see if Tesla finally gets serious about bumpers front and rear as appears to be the case with Cybertruck next as well. Hand brake would be greatly appeeciated as well.

[@THEKITPLUG]

The vertical integration that the gigacast affords them is brilliant. I wonder how hard it is to update the cast based on the new findings.

[@MindofMatter]

I'm glad to have heard of caresoft now. I'm about sick of that other vehicle tear down channel. You guys know that one I'm talking about

[@citizenblue]

I really enjoy watching the Autoline channel take a pretty fair and balanced approach to Tesla vehicles. Edit: I believe electric vehicles are an inevitability from an engineering standpoint. Lower moving parts count and less tuning/maintenance requirements are key factors.

[@urbanstrencan]

What an interesting technology inside truck, great work and videos

[@jbarvideo12]

Beautiful, detailed explanation of engineering and implementation to reduce cost and provide workers' safe, easier assembly of both white bodies.

[@missingpiece2071]

excellent impartial information

[@mjp0815]

Wow, very informative and I think they managed to say "exoskeleton" zero times... 😅

[@voidthewarranty1429]

Brilliant coverage of the castings.

[@JamesKennedyio]

Camera guy was listening, nice filming!

[@Miata822]

Great video! I sure hope the glued-on and snap-fitted stainless body panels put the last of the "Exoskeleton" talk to bed.

[@Holeyguagaamoley]

Yes but you know the faithful will keep saying it!

[@boostav]

The only snap fit is the brow, the rest is bolted.

[@Miata822]

@@boostav Valid, but still not structural.

[@tarasilchuk167]

Body actually contributes 30% to overall registry so he got it wrong there

[@Martinmack333]

​@tarasilchuk167 what are you bagging your comment on? There are no facts in evidence that the body panels are anything but decorative.

[@mibars]

Thank you for the analysis, it all makes sense from manufacturing perspective. It also shows how different type of a vehicle it is compared to a regular truck, it's more like a large unibody car with a unique trunk. I wonder if Tesla intends to use experience gained with a Cybertruck to build an actual truck.

[@chevypas]

I like this Sean Conery character

[@sergiomessina2037]

Kinda John Travolta-ish...

[@Cross-xm2fr]

Obadiah Stane dropping knowledge

[@mcRydes]

very cool demonstration of Tesla engineering.

[@markplott4820]

caresoft is Clueless , MUNRO has the upper hand. caresoft is out of their LEAGUE.

[@mcRydes]

@@markplott4820 ??? I'm not sure I understand what you meant.

[@christopherhale580]

Fascinating review

[@michaelmackey754]

Great video!

[@SolvingTheMoneyProblem]

Epic insights.

[@sergioantinari805]

Grateful for this LECTIO MAGISTRALIS !

[@mb345]

When Terry put those gloves on he looked like central casting for a hitman. haha.

[@charlesrovira5707]

Wow! This was a great look at the *CyberTruck.*

[@elvinthalund5193]

The stamping was of the CyberHammer

[@dhall936]

@elvin. Thanks for the clarification on the Tesla stamping. I originally thought the frame was stamped by Thor's hammer. This new insight will save me from possibly sounding foolish and ignorant in a party 🎉cocktail conversation. Learn sumpun new everyday.

[@david88va]

Everytime I've worked on a car, this is the type of designed that came to mind as how it should be done

[@balaji-kartha]

Would like a breakdown of the Chinese competitors who have come up the learning and manufacturing curve faster than anyone anticipated. How are their cars from the inside ?

[@fiddlerJohn]

Great info. Thanks.

[@V10PDTDI]

Very refreshing to see a real Engineer talking unbiased about what Tesla is doing I’m just coming from Sandy Munro last video what a difference hope that John doesn’t go back to Sandy he is going to loose all credibility.

[@snookmeister55]

Good show. Thanks.

[@joelny2000]

This is great and the Cybertruck frame construction is an amazing step forward from the Model Y, but it seems like the stainless ended up being purely aesthetic and not an "exoskeleton". It seems that they could have used a much simpler and more cost effective material that HFS for the exterior and save a ton of money even if it has to painted.

[@davisdesigns1153]

What's the repairability for this type of setup?

[@health101DOTorg]

I'm super curious what those two square openings are in the cab/bed wall of the Cybertruck, just below the cab/bed window. They would locate behind the rear seats. Can't be ventilation. Is it to allow pressure from slamming the door to get to the bed area so people's eardrums aren't pressurized from a door slam?

[@highlanderapparel]

When I worked at Bud stamping. Taylor Steele meant 2 pieces. Well moved together on top of each other out of Taylor Steele. The Highlander.😊

[@thomosburn8740]

Tesla did remove adjustable lumbar support in the passenger seat in Model Y, so they are certainly known to remove a feature or two in the name of cost cutting. No more stalk behind the steering wheel must also save them some money.

[@captiannemo1587]

It’s interesting to see what gets spray on protecting and what doesn’t.

[@buggelux]

Much better, I love it.

[@frankkerze9608]

1984 Pontiac Fiero Mill & Drill process is used on the casting bolt attachment points.

[@zbigniewteterycz1571]

SUPER IDEA . POZDRAWIAM WSZYSTKICH BARDZO SERDECZNIE .

[@eddiegardner8232]

Giving Sandy Munro a run for his money.

[@markplott4820]

see - MUNRO @ SAE WCX 2024, video.

[@bikepacker9850]

Not really ... He has zero personality.

[@sergiomessina2037]

What happened with Sandy, do you still colaborate on videos?

[@Alhussainba]

Sandy used to be great before he lost his marbles, I used to think he has a lot of bias for Tesla (which is fine, we all have our own biases), but his video about the layoffs proved that he worships Elon, it is no longer bias, he directly lies to himself and to the audience. He convinced himself and is trying to convince the audience that what musk does is correct, even if it contradicts his beliefs, how many times did he criticize Douglas or ford for not innovating and rejecting engineering ideas to save pennies? and then he comes and says charging will not improve therefore fire all the charging engineers? maybe it will not improve in your lifetime old man.

[@markplott4820]

@@Alhussainba - Sandy is a LUCENT and Clarity as ever. even MORE so , that he has CUT off E for Electric and stopped taking BRIBES from LEGACY auto for Reviews. they DONT like Sandys HONEST opinions , and Sandy CUT them OFF as well.

[@JOHNTSHEA]

Interesting. But there are good reasons why there are no cast aluminium airplanes or ships, and alunimium cars use sheet and forged aluminium. Castings are brittle and heavy compared to forged and pressed metals. The Corvette C8 uses large aluminium die-castings in its structure, but I can think of no other example. As for unity and simplcity, the Soviets thought milling parts from 60 foot long aluminium billets was a good idea for the TU-144 SST “Concordski” but they found that 60 foot long billets can result in 60 foot long cracks. Structural joints ans changes of material can act as rip-stops to limit cracks.

[@hagestad]

10:25 its more likely that if they had to weld the outside panels to the body it would discolor/warp the metal not to mention drives the costs up by taking time.

[@tmuny1380]

This is simply amazing ! I can't wait for 2035 when all cars will be made like this ! All the combusters can walk the work if they don't like it !

[@atenrok]

They won't be.

[@arsni23]

Thank you guys for these videos! Very educational and interesting. Imo you just grabbed the lead for Tesla teardown. Some other channels just make weird elmo-crybaby-videos laetly.

[@jwstolk]

A bolted front motor mount would save a bit for weight for the rear-wheel drive models.

[@DougWedel-wj2jl]

At 18:08 you were saying they mixed in some steel parts of the frame with the aluminum. Steel can bend vs aluminum will want to snap.

[@markplott4820]

IF, you strike the Gigacastings , NOTHING happens , no Damage. IF , you strike Conventional Stampings & wields , there is MAJOR damage from LIGHT impact.

[@santiagohills3997]

Looking at the buttress at 15:20 makes it clear where Rivian’s gear tunnel came from.

[@hereigoagain5050]

Didn't the R1T come to market before the Cybertruck? It is probably a coincidence, or maybe Tesla did a tear-down of the R1T.

[@brandywell44]

On the 48V infrastructure, why not go higher to 120V (US domestic voltage)? Higher voltage infrastructure means less electrical resistance which could mean lighter wiring harnesses and motors (HVAC, power seats, etc. (not the propulsion drive motor which I understand uses a much higher and separate circuit voltage of its own anyway)).

[@morrisandsonstowing7286]

I would be interested to see how the castings are attached to the cab structure...

[@patrickshanghai2064]

fascinating stuff. thx guys and thx Tesla.

[@tycurtin7565]

Since the stainless is just for looks, it would seem they could make this same truck in plain old steel if they wanted to. Maybe a cheaper model like that is in the future.

[@brandywell44]

...or plastic, like the MCC Smart cars. Owners used to be encouraged to buy spare panel sets. You could change the body panels for a different colour/design set in hours. On the subject of the stainless panels, has anyone done a polished panel set?. It may look good but be dangerously dazzling in strong sunlight.

[@FrankGallagherr]

Tesla is the best car company ever! No gas stations, No oil changes, No smog check, No corrupt dealership, No catalytic converter and as fast as a $650,000 Lamborghini

[@praero551]

And safer than any other car on market, by far!

[@gnoxycat]

You aint joking about faster than a Lambo. My friend and I had the opportunity to flog my Model S and his Lamborghini Aventador up a closed mountain and he couldn't keep up.

[@alanmay7929]

bullshit! its literaly the worst car company ever! totally useless cars that are basically all the same way less capable than an ICE... there are 35 years old toyota hilux with 90hp that are working harder than that tesla piece of garbage in very harsch environments around the world! that tesla truck is literaly impossible to modify let alone do anythng with! a toyota hilux can be converted into 6x6 chassis extended, payload improved, bigger fuel tanks for tons of applications from RV to overlanding rig to rescue, firefighter, ambulance..... ICE are just more capable.

[@alanmay7929]

the 1000hp tesla semi barely hauls 82,000lbs while 650hp diesel semis have been hauling about 4x that load for tousands of miles even on unpaved roads crossing deserts, rivers... to supply remote communities and much more.

[@alanmay7929]

resla factories just like everything else was built using oil and ICE which literaly worked 24/7 not something an EV can even dream of.

[@suresh_elonbro]

if its not really an exoskeleton and just body panel bolt on, they can do a aluminum version of it? for europe? reduce weight, more sporty, carry more?

[@elvisd8832]

Finally got to see what is behind the front fender. Looks like it can be repaired, it was one of my concerns. I doubt that anyone will be making aftermarket body parts though. Does anyone know if one can go to a tesla service centre and be able to get parts directly as an owner?

[@fredbloggs5902]

Yes you can, Bjorn Nyland has covered this.

[@MaxChipz]

Pepsi Sandy Munro also quenches the thirst for knowledge.

[@nicolasloiseau8971]

Very good🤩

[@ashisdas4971]

So based on the presentation, it confirms, it is not even a sudo exoskeleton, traditional unibody with front and rear castings with a battery for a floor and a tough skin made from stainless steel.

[@davidbeppler3032]

Yep, exactly what GM has been building for decades. Unibody. Just no welds, 50% lighter, stronger, and build in 1/4 the time. Other than those minor details. Exactly the same.

[@AuralioCabal]

Have not bought a new GM product since my brand new Buick Grand National in 1987, and will never buy a GM ever again,no GM quality and staying away from STEALERSHIPS!

[@markplott4820]

Hybrid Unibody , w/ Massive Gigacastings FRONT & REAR, 4680 Cell Structural battery pack. Bullet Proof skin 1.8mm HFS . Tesla ARMORED Windows & STRUCTURAL Roof.

[@markplott4820]

@@davidbeppler3032 - gm , doesn't make the SAFEST cars on EARTH.

[@kazedcat]

I don't think you can call it a unibody. You have the front casting independent of the rear castings. So it is a multi body framing.

[@AllistairNeil]

These guys make Sandy bombastic!😅

[@mosca3289]

Fantastic

[@ranig2848]

Everyone was saying legacy will catch up to Tesla... what we're seeing here is Tesla increasing their lead. They used to be 3-5 years ahead, now they're extending it to 5-7 years... maybe 10. These technologies, as they scale, significantly reduce costs of manufacturing and parts - and would make it close to impossible for legacy to catch up. Once Chinese carmakers make it to america, Tesla will be the only car maker ready and able to compete. Legacy will be toast. Some would buy them due to 'tradition' or some other nonsense but everyone else would prefer better vehicles for lower prices.

[@bobbbobb4663]

BingeCo 10 years behind King BYD now! Every day, new product from two guys in a warehouse in Dongguan! Adrian still pumping out 10 year old product calling it new!

[@airheart1]

Not getting me to buy a Chinese car. Until the CCP goes and gets replaced with some decent form of government. Then, I’d consider putting my money into a Chinese company. Until then, nope.

[@markplott4820]

TESLA is 100+ years ahead of LEGACY trucks.

[@erichschindl6530]

Thanks for the video! - So, for my 2.8m long three-seater small car for all terrains, similar to the original Smart two-seater, I think of a stable chassis and the plastic cabin sits on it (similar to eHang216). Or I make the whole car out of a single part? - The Cybertruck is too complex for me.

[@thomasgerber1472]

So the stainless steel exoskeleton is just a myth. The panels are completly useless from a structural standpoint. Just tacked or glued on for show effect. The weirdest fashion statement the car world has ever seen. Usually designers walk the extra mile to make things look rich or fancy or expensive, here they did walk 100 extra miles to make it look like a mad max home built.

[@DougWedel-wj2jl]

See any 20 year old truck and you see it loaded with rust. That won’t happen to the Cybertruck.

[@tonybella3642]

What happened to the whole exo skeleton frame design with the cyber truck?

[@etnapierala]

In 15:00, what are those black-outlined white dots all over the upper part of the chassis?

[@jamfamreptiles1286]

I applaud Tesla and the keep it simple but smart, I work in a collision center and the auto industry for 35 years and I questioned so many times why manufactures offer excessive variations of the same vehicle like Dodge Ram the front grill has 7 or more different options 5 different mirrors, 5 different wheel options 15 different paint colors ect.... That process of assembly is overloaded and think about the cost in design of that many parts for the same vehicle, warehouse space to stock ect.. all this to try to offer more variations to the customer to outdo their competition. every manufacturer has been in a mindless fog of lather rinse repeat withought trying something different likeTesla has been doing.

[@tarasilchuk167]

Great video but got one important fact wrong. The stainless steel body actually contributes 30% overall rigidity

[@snookmeister55]

The castings also contribute to rigidity.

[@highlanderapparel]

The Budd company in Detroit Pioneer using glue. The Highlander.😊

[@Scott-sm9nm]

Easter egg -- > EPC: Homepage | Cybertruck | 10-BODY | 1010 Body Panels Closure Panels

[@captiannemo1587]

How easy is it to rebuild from a quarter impact?