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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.
Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.
Elon Musk
Tesla’s Roadster appearance at SpaceX has merger watchers talking
Tesla’s next generation Roadster was spotted at SpaceX’s Hawthorne headquarters, two weeks after its unveiling.
Tesla’s next generation Roadster turned up at SpaceX’s headquarters in Hawthorne, California on Wednesday, less than two weeks after the car flew off a ramp at its unveiling in Texas.
Photos shared on X by SpaceX Engineer (@DeannaRiceSPCX) show the new Roadster parked outdoors beside the famed Falcon 9 that stands outside company headquarters at the corner of Crenshaw Boulevard and Jack Northrop Avenue. Rocket B1019 was the first orbital-class booster ever to land after a launch on December 21, 2015 after it sent 11 Orbcomm satellites to orbit and then flew back to Landing Zone 1 at Cape Canaveral, which would be the first landing in what became SpaceX’s reusable rocket program. SpaceX chose not to fly it again. After a test fire in Florida, the booster was shipped to Hawthorne and raised upright as a permanent monument in August 2016, as Teslarati reported at the time. Putting the Roadster, which flies on SpaceX cold gas thrusters, next to the rocket that started SpaceX’s landings is symbolic in itself.
Small car, big rocket ambitions 🚀🚗 #roadster #falcon9 #spacex #tesla https://t.co/H32xUSXoCl
— Deanna Rice (@DeannaRiceSPCX) October 29, 2026
The Thrust and Rocket versions of the Roadster use cold gas thrusters fed by composite overwrapped pressure vessels, the same type of tank SpaceX flies on Falcon 9, and Elon Musk described the car as the work of Tesla and SpaceX engineers working together. Tesla lists 0 to 60 mph in under 0.9 seconds for Thrust and under 0.59 seconds for Rocket, while the base Performance model relies on a fan and ground sealing system for grip, as Teslarati detailed in its breakdown of the three Roadster configurations.
Tesla has kept the car in the spotlight since the October 15 event near Waco. Last week, the company posted a video of the Roadster’s fighter jet inspired cockpit, including a Track Mode screen with a “Thruster · 5,500 PSI” readout, which we covered in our look at the Roadster’s center display. Musk also said owners will be able to ask the car to perform the stunts autonomously, and promised a looping track at Tesla’s Texas headquarters.
The visit comes as special committees at Tesla and SpaceX weigh a possible merger, a step Musk confirmed on SpaceX’s third quarter earnings call. The Roadster, built on SpaceX hardware, has become one of the clearest examples of the two companies already building products together.
Musk said at the unveiling that Roadster production will begin in 2028. Reservations are open with a $50,000 payment, Thrust is listed as a limited release and Rocket is invite only. Tesla says the car is not approved for public road use.
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Verizon, AT&T and T-Mobile are trying to shut Starlink out before FCC vote
AT&T, Verizon and T-Mobile want 290 MHz cut from an FCC satellite plan before Thursday.
AT&T, Verizon and T-Mobile are asking the Federal Communications Commission to pull nearly 300 MHz of spectrum out of a proposal that would let satellite companies like SpaceX offer cell service directly to ordinary phones. The request lands one day before the agency votes on it.
The FCC will vote Thursday, October 29, on a notice of proposed rulemaking that would make an additional 482 MHz available for direct to device service, expanding the number of eligible bands from five to 13, according to the FCC fact sheet. It would also scrap the rule requiring a satellite operator to lease spectrum from carriers, replacing it with a certification that the operator has coexistence agreements in place or holds the terrestrial license itself.
That second path matters for SpaceX. As Teslarati reported earlier this month, SpaceX agreed to buy Grain Management’s nationwide 800 MHz portfolio to turn Starlink Mobile into a full US carrier, adding to the spectrum it already bought from EchoStar.
The carriers want two bands removed, 2.5 GHz and 3.45 GHz, which make up 290 MHz of the 482 MHz on the table. Through industry group CTIA, they argued that about 300 million users depend on those bands and that satellite operations in them are not technically feasible. T-Mobile, which calls 2.5 GHz the foundation of its Ultra Capacity 5G network, said in its own filing that satellite interference could wipe out up to 96% of a cell site’s uplink coverage area and cut uplink speeds by 88% to 99%.
Executives from all three carriers met with FCC staff on October 20, and T-Mobile CEO Srini Gopalan met separately with FCC Chairman Brendan Carr. T-Mobile’s role stands out because it is still SpaceX’s US launch partner for Starlink Mobile. The three carriers have also teamed up on their own satellite joint venture to pool spectrum, a move widely seen as a response to Starlink.
SpaceX is asking for the opposite. In an October 23 filing after meetings with FCC staff and commissioners’ offices, the company asked regulators to add the 902 to 928 MHz band to the proposal. “Doing so now saves time later,” SpaceX wrote. The company also asked the FCC to modernize interference rules and align satellite deployment requirements with those for terrestrial cell networks, saying the goal is to let satellite and ground networks work together so Americans stay connected wherever they are.
The carriers have not been shy about how they view SpaceX as a competitor. On Verizon’s third quarter earnings call Monday, its chief executive said Starlink Mobile “just can’t compete with a terrestrial network” and estimated SpaceX would need four to six years and $300 billion to $500 billion to build a full US carrier network.
Thursday’s vote will not settle which bands survive. Adopting the notice opens a public comment period, with final rules to come later in the proceeding. The FCC already considered and rejected 2.5 GHz for satellite coverage once, in 2024. SpaceX also is not the only satellite player watching: the FCC approved Amazon’s $11.6 billion acquisition of Globalstar on October 27, giving its planned direct to device fleet its own mobile satellite spectrum.
News
Tesla Semi catches fire in California: what we know
A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.
The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.
There were no injuries reported.
🚨 A Tesla Semi reportedly caught fire, with California Highway Patrol confirming. The Semi was on I-880 SB
An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year
— TESLARATI (@Teslarati) October 28, 2026
The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.
However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.
@Tslachan From on of the videos looks like it’s an old Semi (not the refresh version that recently started production) https://t.co/KzwmR2kXow
— Area Under The Curve 🎗️ (@AreaUnderCurve) October 28, 2026
At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.
The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.
The truck’s driver said that the Semi caught fire, but he did not have an explanation.
An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.