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Tesla Cybertruck lead engineer shares insights on deep integration and vehicle development
Tesla Cybertruck Lead Engineer Wes Morrill recently shared some insights on the electric vehicle maker’s deep integration and unique approach to car design in a recent post on social media platform X. As could be seen in the engineer’s post, it is Tesla’s intense attention to detail that ultimately makes the company’s vehicles as disruptive as they are today.
Anyone informed who looks at the Tesla Cybertruck would know that the vehicle is a symphony of automotive engineering. Tesla, however, took some time before it reached this point. As per Morrill in his post, Tesla in its early days utilized different teams with collaborative goals in vehicle design. Adopting this system allowed the company to make great cars, but the designs of the vehicles themselves were not optimal.
“A well known example – early days of Tesla there was a battery team and separately a vehicle structures team. Structures team designed their vehicle body to meet given requirements of strength, crashworthiness, torsional stiffness, etc. Likewise, the battery team designed their part to be self contained, it could survive durability, accidentally being dropped, being hit in a crash, etc.
Good analysis – this is what happens when teams work together to make the best product. https://t.co/XAXf70k3jc— Wes (@wmorrill3) September 14, 2024
“As a result, we ended up with was a super dense battery in a strong box like structure, which was then Installed into the vehicle which had a nice space for it to mate into. There were no issues with integration, everything fit together perfectly and met all product goals. It achieved one of the highest crash safety ratings measured at the time.
“But we had a box full of battery cells that was installed into another empty box shaped receptacle on the body. A box in a box. When you simplify it down that far it sounds obviously wrong. The two organizations had achieved their goals, worked together without friction, and the product met its overall goals. Yet the product ended up with a clear lack of optimization as a result of the organizational boundaries of the two teams working in isolation. Nothing was wrong, but it wasn’t optimal,” Morrill wrote.
The Cybertruck Lead Engineer noted that Tesla learned from these experiences, and the company adapted. This is how innovations such as the structural battery pack—which is now being simulated by electric car makers in China—came about. Morrill stated, however, that such changes may require large organizational changes, and there has to be a drive to make the best product regardless of ego.
Have you heard of Conway's Law? It's an interesting observation about the root cause of why large organizations usually make products worse.
In 1967 Melvin Conway wrote "Organizations which design systems are constrained to produce designs which are copies of the communication… pic.twitter.com/SetWd6OfTe— Wes (@wmorrill3) September 14, 2024
“Before the next product was designed, the battery team gave responsibility of the battery structures also to the vehicle structures team. On this iteration, we ended up with the structural battery, which is an integral part of the body and crash structure. Without it, the vehicle body will not work. It’s the literal floor for the vehicle. But the redundancy is gone and the design is more efficient as a result. This vehicle also achieved one of the highest crash safety ratings measured at the time.
“This is a super obvious example (in retrospect) and solved with a fairly large organizational change but you can also see this happen in small technical decisions and doesn’t require structural change to fix. Someone just needs to question if there is a better solution in a team open to criticism. This mindset to work together to make the best product regardless of ego is where you end up with the most innovative products.
“Some smaller examples have been seen when inspecting Cybertruck design. The chassis air suspension which is used to pressurize the battery pack to prevent water ingress. The subwoofer which utilizes the air volume of the body side instead of making the enclosure larger. Centralized zonal vehicle controllers instead of many small distributed controllers. Doors which use the exterior surface as a crash intrusion beam. The pedestrian warning system used as a horn. The list goes on. The excitement and motivation by everyone involved to work across boundaries and actively break down Conway’s Law is one of the many reasons I love working at Tesla,” Morrill wrote.
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Tesla Giga Berlin plant manager faces defamation probe after IG Metall union complaint
Prosecutors in Frankfurt (Oder) confirmed they have opened a defamation probe into Gigafactory Berlin plant manager André Thierig.
Tesla’s Giga Berlin plant manager is now under investigation after a complaint from trade union IG Metall, escalating tensions ahead of next month’s works council elections.
Prosecutors in Frankfurt (Oder) confirmed they have opened a defamation probe into Gigafactory Berlin plant manager André Thierig, as per a report from rbb24.
A spokesperson for the Frankfurt (Oder) public prosecutor’s office confirmed to the German Press Agency that an investigation for defamation has been initiated following a criminal complaint filed by IG Metall against Thierig.
The dispute stems from Tesla’s allegation that an IG Metall representative secretly recorded a works council meeting using a laptop. In a post on X, Thierig described the incident as “truly beyond words,” stating that police were called and a criminal complaint was filed.
“What has happened today at Giga Berlin is truly beyond words! An external union representative from IG Metall attended a works council meeting. For unknown reasons, he recorded the internal meeting and was caught in action! We obviously called police and filed a criminal complaint!” Thierig wrote in a post on X.
Police later confirmed that officers did seize a computer belonging to an IG Metall member at Giga Berlin. Prosecutors are separately investigating the union representative on suspicion of breach of confidentiality and violation of Germany’s Works Constitution Act.
IG Metall has denied Tesla’s allegations. The union claimed that its member offered to unlock the laptop for review in order to accelerate the investigation and counter what it called false accusations. The union has also sought a labor court injunction to “prohibit Thierig from further disseminating false claims.”
The clash comes as Tesla employees prepare to vote in works council elections scheduled for March 2–4, 2026. Approximately 11,000 Giga Berlin workers are eligible to participate in the elections.
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Tesla wins FCC approval for wireless Cybercab charging system
The decision grants Tesla a waiver that allows the Cybercab’s wireless charging system to be installed on fixed outdoor equipment.
Tesla has received approval from the Federal Communications Commission (FCC) to use Ultra-Wideband (UWB) radio technology in its wireless EV charging system.
The decision grants Tesla a waiver that allows the Cybercab’s wireless charging system to be installed on fixed outdoor equipment. This effectively clears a regulatory hurdle for the company’s planned wireless charging pad for the autonomous two-seater.
Tesla’s wireless charging system is described as follows in the document: “The Tesla positioning system is an impulse UWB radio system that enables peer-to-peer communications between a UWB transceiver installed on an electric vehicle (EV) and a second UWB transceiver installed on a ground-level pad, which could be located outdoors, to achieve optimal positioning for the EV to charge wirelessly.”
The company explained that Bluetooth is first used to locate the charging pad. “Prior to the UWB operation, the vehicular system uses Bluetooth technology for the vehicle to discover the location of the ground pad and engage in data exchange activities (which is not subject to the waiver).”
Once the vehicle approaches the pad, the UWB system briefly activates. “When the vehicle approaches the ground pad, the UWB transceivers will operate to track the position of the vehicle to determine when the optimal position has been achieved over the pad before enabling wireless power charging.”
Tesla also emphasized that “the UWB signals occur only briefly when the vehicle approaches the ground pad; and mostly at ground level between the vehicle and the pad,” and that the signals are “significantly attenuated by the body of the vehicle positioned over the pad.”
As noted by Tesla watcher Sawyer Merritt, the FCC ultimately granted Tesla’s proposal since the Cybercab’s wireless charging system’s signal is very low power, it only turns on briefly while parking, it works only at very short range, and it won’t interfere with other systems.
While the approval clears the way for Tesla’s wireless charging plans, the Cybercab does not appear to depend solely on the new system.
Cybercab prototypes have frequently been spotted charging at standard Tesla Superchargers across the United States. This suggests the vehicle can easily operate within Tesla’s existing charging network even as the wireless system is developed and deployed. With this in mind, it would not be surprising if the first batches of the Cybercab that are deployed and delivered to consumers end up being charged by regular Superchargers.
Elon Musk
Tesla posts updated FSD safety stats as owners surpass 8 billion miles
Tesla shared the milestone as adoption of the system accelerates across several markets.
Tesla has posted updated safety stats for Full Self-Driving Supervised. The results were shared by the electric vehicle maker as FSD Supervised users passed more than 8 billion cumulative miles.
Tesla shared the milestone in a post on its official X account.
“Tesla owners have now driven >8 billion miles on FSD Supervised,” the company wrote in its post on X. Tesla also included a graphic showing FSD Supervised’s miles driven before a collision, which far exceeds that of the United States average.
The growth curve of FSD Supervised’s cumulative miles over the past five years has been notable. As noted in data shared by Tesla watcher Sawyer Merritt, annual FSD (Supervised) miles have increased from roughly 6 million in 2021 to 80 million in 2022, 670 million in 2023, 2.25 billion in 2024, and 4.25 billion in 2025. In just the first 50 days of 2026, Tesla owners logged another 1 billion miles.
At the current pace, the fleet is trending towards hitting about 10 billion FSD Supervised miles this year. The increase has been driven by Tesla’s growing vehicle fleet, periodic free trials, and expanding Robotaxi operations, among others.
Tesla also recently updated the safety data for FSD Supervised on its website, covering North America across all road types over the latest 12-month period.
As per Tesla’s figures, vehicles operating with FSD Supervised engaged recorded one major collision every 5,300,676 miles. In comparison, Teslas driven manually with Active Safety systems recorded one major collision every 2,175,763 miles, while Teslas driven manually without Active Safety recorded one major collision every 855,132 miles. The U.S. average during the same period was one major collision every 660,164 miles.
During the measured period, Tesla reported 830 total major collisions with FSD (Supervised) engaged, compared to 16,131 collisions for Teslas driven manually with Active Safety and 250 collisions for Teslas driven manually without Active Safety. Total miles logged exceeded 4.39 billion miles for FSD (Supervised) during the same timeframe.
Tesla Giga Berlin plant manager faces defamation probe after IG Metall union complaint
Tesla wins FCC approval for wireless Cybercab charging system
