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.

[@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.

[@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?

[@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.

[@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.

[@brianstanfill2114]

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

[@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!!

[@TheJazzper1970]

Excellent video, thanks.

[@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.

[@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.

[@8ballphilc]

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

[@jonlivingstone]

What a great analysis!

[@jaydeister9305]

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

[@kqschwarz]

Fantastic insights. THANK YOU.

[@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.

[@davisdesigns1153]

What's the repairability for this type of setup?

[@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.

[@deltajohnny]

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

[@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.

[@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.

[@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?

[@ivankuljis1780]

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

[@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.

[@CasperCastrol-rq8ed]

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

[@etnapierala]

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

[@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

[@zilogfan]

More of this content, more detail Please.

[@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.

[@michaelmackey754]

Great video!

[@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.

[@alex135789]

As always very impressed. Much appreciated. Thank you.

[@ernesttravers7517]

Excellent Fellas Well done

[@flattire707]

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

[@captiannemo1587]

How easy is it to rebuild from a quarter impact?

[@tonybella3642]

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

[@urbanstrencan]

What an interesting technology inside truck, great work and videos

[@markadams7799]

Excellent. Thanks for making this video

[@SolvingTheMoneyProblem]

Epic insights.

[@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?

[@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.

[@electriccars-EV]

Wow I love this video!

[@DougWedel-wj2jl]

At 7:50 you talk about these steel inserts the bolts get threaded on to. Are these flat like washers or more like a T shape, with a big round part on the top with a tube going down?

[@charlesrovira5707]

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

[@jbarvideo12]

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

[@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.

[@kb8570]

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

[@JamesKennedyio]

Camera guy was listening, nice filming!

[@sergioantinari805]

Grateful for this LECTIO MAGISTRALIS !

[@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

[@frankkerze9608]

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

[@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.

[@morrisandsonstowing7286]

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

[@missingpiece2071]

excellent impartial information

[@voidthewarranty1429]

Brilliant coverage of the castings.

[@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

[@Dkrpan59]

Can the gigs castings be repaired from a wreck

[@adamgrundy4327]

no but if you damage them the car will be deemed totalled.

[@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.

[@DougWedel-wj2jl]

16:10 What IS this piece??? Where does it fit in relation to the rest of the truck? It’s actually a separately cast part??

[@DougWedel-wj2jl]

D pillar?

[@markplott4820]

YES, the side rails are Minor Castings , made up of Recycled casting scrap. they Dont have to be TOUGH as the Sails are NON structural. they are Wielded & bonded in place. they are Different materiel from the MAIN rear Gigacasting. there are 4 pieces , 2x for each side.

[@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.

[@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 ?

[@snookmeister55]

Good show. Thanks.

[@mjp0815]

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

[@Cross-xm2fr]

Obadiah Stane dropping knowledge

[@captiannemo1587]

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

[@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.

[@andrewdubose9968]

He makes it sound so riveting.

[@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.

[@fiddlerJohn]

Great info. Thanks.

[@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.

[@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.

[@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.😊

[@DougWedel-wj2jl]

I’m wondering about the fire wall, the vertical metal that in ice cars separated the engine compartment from the cabin. Why is it vertical, straight up and down? Does that serve some purpose? Because I can’t think of any. It might work better canted at an angle leaned forward or back or some corrugated shape. I don’t know the engineering behind this but just thought making it completely vertical didn’t look like it served any purpose beyond ...we always did it this way and had no reason to change.

[@DougWedel-wj2jl]

12:10 the vertical that separates the cabin from the cargo box is canted at two angles, like I expected the front, the firewall to be.

[@markplott4820]

its a Gigacasting , its Structural. its Thinner than Conventional fire wall.

[@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.

[@DougWedel-wj2jl]

I wonder how much twist the frame has when the battery pack isn’t bolted in, to see how much the battery pack contributes to keeping the truck from twisting?

[@markplott4820]

ZERO .

[@Alss383]

It has to be zero. When I replace the battery packs on Models S-E-X-Y I never have issues opening doors or notice any body flex while it's on the lift. We've even pushed cars out the shop without batteries and they feel solid. I'm sure it makes it stronger with the battery in place. They use a bunch 13mm and 16mm bolts to hold the battery in place.

[@buggelux]

Much better, I love it.

[@jwstolk]

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

[@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.

[@chevypas]

I like this Sean Conery character

[@sergiomessina2037]

Kinda John Travolta-ish...

[@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)).

[@pa3109aTn]

Great content. Do gigacastings make vehicles more expensive to repair?

[@mikes-wv3em]

what do you think? duh. castings crack. metal bends.

[@streddaz]

@@mikes-wv3em no one straightens chassis these days. With any car, if it's more than a fender/body skin replacement it's written off.

[@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.

[@zbigniewteterycz1571]

SUPER IDEA . POZDRAWIAM WSZYSTKICH BARDZO SERDECZNIE .

[@david88va]

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

[@patrickshanghai2064]

fascinating stuff. thx guys and thx Tesla.

[@mosca3289]

Fantastic

[@royh6526]

Does the Model 3 use giga-casting?

[@TheDoggydogworld]

Apparently not. The refreshed "Highland" version was supposed to have front and rear gigacastings, but the first ones coming out of Shanghai did not.

[@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.

[@nicolasloiseau8971]

Very good🤩

[@oisiaa]

I understand that the body panels are stainless steel, but the frame (minus the castings) is steel, right? How will this vehicle hold up against a high corrosive environment such as road salt? Think it will last 30 years on the road without the frame rusting out?

[@markplott4820]

100% Dipped and e-Coated . Cybertruck , does not RUST .

[@kazedcat]

I think they are coated with chromium for rust protection.

[@ALXXR63AMG]

If the Cybertruck had TITAN reinforcements between Battery and Body could they have made a Pass through lose floor ?

[@mb345]

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

[@gandmemoney]

Do the castings make for a quiet ride?

[@AuralioCabal]

Torsional ridgidity is probably better than traditional unibody, that and the battery pack being one solid piece as how it is glued together as shown in Munro Live battery pack teardown.

[@markplott4820]

YES , and Roof & all windows are Insulated for NVH. you can also see NVH patches applied to the Gigacastings.

[@snookmeister55]

It seems that Teslas are becoming very quiet and it's particularly noticeable in the Cybertruck.

[@markplott4820]

@@snookmeister55 -, Cybertruck is outselling the Hummer EV & Silverado EV, let that sink in.

[@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.

[@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.

[@HH-bc2nz]

2:49 how he uses the gloves with the full black suit, looks like Agent 47 from Hitman is preparing for his mission