But At What Cost? Tesla Cybertruck Door Teardown

Carl assesses the disassembled doors of the Tesla Cybertruck, weighing the costs of the design decisions against those of similar vehicles.
Munro Live is a KZbin channel that features Sandy Munro and other engineers from Munro & Associates. Munro is an engineering consulting firm and a world leader in reverse engineering, costing, and teardown benchmarking.
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#tesla #cybertruck

[@henrybrandt1057]

Carl is a natural at teaching. Thank you for another educational lecture.

[@MunroLive]

Thanks for watching!

[@SuperLala33]

Very clear and precise, great explanation. Best on this channel yet i must say :)

[@mousetreat]

Keep nerding out! That's what we're here for. I learned something today!

[@poporbit2432]

This is exactly why I watch your videos. Learning this level of detail is so value and is unique to your videos.

[@Dalisu87]

Carl is so good at explaining complex stuff, from his cadence and giving clear examples wrapped in controlled nerdy passion.

[@mjp0815]

Hey this is exactly what I come here for. Next level integration, what a great team at Munro.

[@larryellison1788]

Very clear and concise explanation. Great job. I am amazed at all of what the Munro group does and it continues to showcase the advanced engineering that goes into Tesla autos.

[@WilliamDye-willdye]

His explanation at 11:30 of injection/casting shrink marks is much more concise than anything I've seen before. I was messing with finite element analysis, but all I had to do was draw a circle.

[@ChristianKurzke]

This ammount of optimisations is really only possible because of vertical integration. As he says in the video, in traditional manufacturing every team is only incentivised to optimize their module. You need a lot of collaboration to create a global maximum optimization where you can intelligently trade door panel features against battery range. Well done, Tesla!!

[@okharren]

Great video, love the "shrinkage" explanation. 😂

[@danharold3087]

The frameless doors on the CyberTruck a style choice. The door controller module enables Tesla to assemble and test the doors independently. A bit of the unboxed system influence. Having fixed a few window regulators I love the huge access hole in the Tesla door.

[@davidstockbridge]

Carl, thanks for explaining the details. Suggest that you stage your demo space ahead of time, so that you're not stacking assemblies on top of another brand's assembly. Remember to define your terms for those unfamiliar with car design.

[@Simon-gk9ug]

Awesome vid as always guys and props to Carl for his knowledge and geek moment 😅

[@jgramsey]

Title of the video could be, "Managing design trade-offs" excellent discussion of engineering trade offs!

[@jackcoats4146]

I love the overall systems approach. Each item is important, but the overall system is still the point!

[@redcrumb]

thank you for the explanation!

[@MunroLive]

You're very welcome!

[@JigilJigil]

Another amazing video by Munro and Carl.

[@MunroLive]

Glad you enjoyed it

[@johnmanzer9717]

Love watching Carl videos! More Please!!

[@dennisfahey2379]

Great explanation. The annoying thing about engineering is the inevitable tradeoffs. I loved the line "This solves the problem; now we have three more." - Ain't it the truth. And of course its got to be as low cost as possible. As for the 48V window motor - really its way less of a "big thing" than most think. All those plastic bits are interchangeable with the 12V product. The windings and possibly connector on the brushless motor are all that are changing and they should in fact be lower gauge wire and less expensive. The housing was probably kept to save on parts development. The connector could be very slightly cheaper but its probably not worth the effort (even in volume). When you make this sort of transition there is going to be bureaucratic push back. It often falls upon the big companies with purchasing power to make the call and then everyone benefits. I would really love to find the trade rags for the move from 6V to 12V systems when they needed more wattage for the starter motors on the bigger V8's. That must have been a Holy War of sorts. To be clear there is a HUGE 48V solution market already in place outside of the automotive realm. Migrating those proven solutions (circuits and modules) over is cake - maybe a couple weeks of effort for new from factors and industry compliance. And to be clear the 48V-ness of it is not magical. Anything in the upper voltage below 60V will translate. Nothing magical about 48V except it is part of a standardized portfolio.

[@wtmayhew]

I’ve seen surface pull back on exposed parts quite a few times. Some engineers don’t care or were ordered, “just do it anyway.”

[@caladanian]

The i3-design to showcase the material was transforming a bug into a feature. Smart design 😎 …and I actually liked the surface in the BMW i3 doors and front panel.

[@JeffreyLWhitledge]

“I’m mostly an interior person.” Same.

[@patmcdaniel2016]

Loved the nerd moment, It was very informative.

[@MunroLive]

Glad you enjoyed it!

[@hermanmunster8655]

C'mon guy's, you really want one broken down door to cripple a central system or the cost of a work around. Door module's are so common and isolate common problems while maintaining a fully functioning central system with no need for by pass

[@antoinepageau8336]

Forecast volume and market segment will also drive many design decisions. Great video!

[@wtmayhew]

Thank you Carl, I really appreciate the insight you give us into how assemblies are manufactured.

[@NathanKraemer]

I very much loved the injection molding "nerd moment"

[@knightkrew]

0:55 I believe Tesla is opting to include individual door control modules vs integrating them into the body controller as a test of their "Unboxed" process in a production environment. This allows Tesla to test / homologate individual doors before installing them into the vehicle. Once all the components are integrated into the vehicle a final integration test can be performed by the vehicle itself to ensure everything is working together. This approach is similar to how NASA tests new rocket components where they fly the new parts on old rockets before they fly them as an entirely new rocket. What do you think?

[@1968matrix]

And do not forget the speaker integration... it eliminates two more wires....

[@carvalhoribeiro]

Thank you for such detailed explanations. I really appreciate these videos.

[@MunroLive]

You're very welcome!

[@JT_771]

Great info; thanks!

[@carloslaue1236]

I think they hide the rear emergengy release under a rubber mat because of children... You don't want them physically being able to open the door without any latch... Maybe a mechanical latch with a mechanical lock would work better but then good luck getting out of any mechanically child-locked vehicle.

[@1968matrix]

While we aim for objectivity, we're curious to see which option performs better. Although frameless doors are generally more aesthetically pleasing than traditional doors, they often come with a higher price tag. However, advancements in mass production and engineering can help bridge this gap. A broader perspective can shed light on aspects that many established manufacturers are still struggling to understand.

[@batchint]

carl found out he can be a genius nerd but only in extra special situations… thank you carl… and sandy munro… 🎵

[@djstrobo]

That's very interesting. I like the approach with more expensive tooling. Long term it will pay off.

[@grahammonk8013]

I'm super keen to see some of the optimizations for the "cheap" Tesla.

[@m_sedziwoj]

I still interest what your conclusion would be on this separate module for door. But I think they go with idea of hubs, so hub connect to hub, and hub get all connections for elements close to it. So when you do rework, you don't need to rework all, but up to hub (included)

[@danharold3087]

The move to the door module is part of moving to the unboxed method. This allows them to assemble and test the door as a stand alone unit.

[@ch4.hayabusa]

Could you do high pressure contact cooling of the part to reduce witness marks? Or make a design feature out of the witness marks so they don't have to be hidden?

[@nuvi5480]

The door has a separate module so that it can be manufactured separately, and them just bolted on and plugged in. At least that's my best guess

[@marshalllapenta7656]

Question? Could it be SAFETY protection for that door module? Because of a 48 VOLT system, have we taken that door module apart, at MUNRO? Instead of laser welded those 2 door parts, could they have used glue or adhesive? Are they rushing designs out the door?

[@satoshimanabe2493]

So the emergency door release...is it a single-use (i.e. requires service to reset)? Or is it routinely usable, for example to let kids practice how to get out in an emergency?

[@gustavgron2252]

I love these nerd moments! Im possibly a nerd myself… 😂

[@johntheux9238]

Nice, could you check the tensile strength and elongation at break of their alloy? Might be the highest toughness of any steel alloy.

[@danharold3087]

On this truck and most modern car one would want the cabin to be the "highest toughness". Don't know about the SX but the 3Y and CT use a single hot stamping from ultra high strength steel (maybe some boron) for the inner and outer door rings. These form the sides aka frame of the passenger cabin.

[@jonahbert111]

What came to my mind was, a memory that the Cyber Truck is supposed to float, even function perhaps as a boat. How does that affect the design of the doors? Or am I all wet?

[@kemicbi]

ok I think doors have to be one of the most time consuming and complex pieces to design engineer and manufacture.

[@bradweinberger6907]

It's Teslas vertical integration not Making cross department collaboration more normal when designing a vehicle?

[@CharlesLogstonInTexas]

That cover for the inner door panel is a terrible choice. There is a reason trucks have durable plastic on the lower side of the inner door panels, especially the rear door. It tears easily, I found out the hard way, a very expensive mistake on my part.

[@monkeystealhead]

Conveniently left out the rust problems and the fact that everybody is wrapping their stainless steel Cybertrucks. I can understand why people like no frame on doors, but I prefer framed car doors.

[@darpompie4354]

Agree... Kind of defeats the purpose of using expensive and heavy stainless steel. They could have been out 2 years earlier and had a way better product if they just used aluminum. Stamped light weight panels and nice glossy paint options.

[@markplott4820]

MUNRO - and yet in September 2024 TESLA model Y , outsold in the USA every Full Size Light Trucks , inc F-150 ICE, Silverado 1500, gmc 1500 and RAM 1500. Tesla model Y also outsold Camry, Carolla , Rogue , Equinox and Civic. and same Period TESLA Cybertruck outsold EVERY OEM in USA selling EV Trucks.

[@urishaham2544]

Tesla sadly lost their way with the CT. It should be form follow function, not the other way around. Clearly it's heavier than it has to be and full of compromise. Hope they remedy that for the next gen.

[@MrCarGuy]

I don't think many would complain if Tesla switched to full frame doors

[@j1000a]

It would certainly change the look of the Cybertruck. I do wonder if there are cost benefits as-is.

[@appl314]

What is the safety factor between the tesla and Ford?

[@markplott4820]

MUNRO - what do you think about HEMP door and vehicle Body. this could be Future tech.

[@eternalbalance7703]

100% agree! It's light weight, durable, & won't need paint.

[@AaronAverett]

@12:19 - Is it not possible to design a rib into the part on the opposite to compensate for the shrinkage, so that the result is a flat surface?

[@L33TNINJA51]

Or maybe just make it bulge so that when it shrinks, it ends up flat?

[@1903tx]

@9:37 Why does that panel have a 150mm scale on it?

[@freddymax5256]

.6 mm - that’s small. About 1/2 the thickness of a dime.

[@arnecarlsson9740]

👏👏👏!

[@dwightsimpson18]

Can someone explain all the dots?

[@MunroLive]

They're for 3D scanning.

[@dwightsimpson18]

@@MunroLive Thank you ! How interesting 🧐

[@royh6526]

What? They have a manual release that couldn't be found if you didn't watch this video or read the manual?

[@danharold3087]

BMW, Mercedes-Benz, and Audi use them too.

[@Poxenium]

10:23 Plasticman!

[@Boonedocks]

poor guy is sweating like a 400lb 🐷😥

[@jimanderson4444]

Speak slowly and carefully please, surely this content is worthy of less hurried preasantation .

[@markplott4820]

CARL - its important to note LEGACY trucks Require paint and Dont have ARMORED Glass & Bulletproof body Panels like the TESLA Cybertruck. LEGACY trucks just sit in lots UNSOLD, and rusting. also the LEGACY door can easily be scratched, chipped , dented & Rusted UNLIKE Cybertruck. the BEST part , is NO part. BEST process , NO process.

[@bobbyr8071]

Frameless doors are a gimmick only good for low coupes that are hard to ingress and egress. I don’t know why Tesla uses them because they tend to make good design choice.

[@geomacaulay]

They're just cooler i guess. As there's an association with exotic 2 door sports cars and convertibles.

[@tesla_tap]

What gimmick? They look better, the doors are lighter, and less door material/weight is needed. I've had them on many cars (not just Tesla). Framless also it improves the aerodynamics quite a bit, so the vehicle is more efficient - rather important for EVs. It's a major reason that old ICE designs with framed windows converted to EVs do so poorly in efficency.

[@LazyMax05]

After watching the WhistlinDiesel videos on Cybertruck, not a lot of respect for the corner cutting taken to build this truck.

[@tasd5673]

Really 😂 just wait a few years this will be THE worse look at the M3

[@muskepticsometimes9133]

Using stainless for truck dumb idea. Note stainless more cost per pound

[@henryyiu618]

LOL imagine relying on Cody as an automotive advisor instead of Sandy or Terry.

[@markplott4820]

WD is a fake tuber , and a LIAR . he broke the Crush Cans himself , when he backed off a Flatbed w/o a ramp. WD has been Flagged as a LIAR.

[@infernoking7504]

The only think I liked about the cyber truck is in that video it did take that c4 explosive very well and those bullets but thats legit it I hate everything else.