A Leaked Tesla Report Shows the Cybertruck Had Basic Design Flaws

In May, the German newspaper Handelsblatt began reporting on the “Tesla Files”: thousands of internal documents provided to it by a whistleblower. Among those documents was an engineering report that might give some insight into why the vehicle has taken so long to come to market…

The unique styling of the truck, with its angular plates and stainless steel alloy construction, mean it’s not only hard to manufacture, but will probably be hard to repair, experts say.

Stainless steel is not easy to shape or mold, “Hence the look as if it’s the output of a student in an in-class ‘Pop Quiz Number 1’ for the course ‘Intro to Car Design,’” says Raj Rajkumar, a professor of electrical and computer engineering at Carnegie Mellon University. The material requires specialized welding techniques, and it doesn’t flex easily, which could be dangerous in a crash, when force usually absorbed by a “crumple zone” could be transferred to cabin occupants instead, Rajkumar says.