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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 stands to gain from Ford’s decision to ditch large EVs
Tesla is perhaps the biggest beneficiary of Ford’s decision, especially as it will no longer have to deal with the sole pure EV pickup that outsold it from time to time: the F-150 Lightning.
Ford’s recent decision to abandon production of the all-electric Ford F-150 Lightning after the 2025 model year should yield some advantages for Tesla.
The Detroit-based automaker’s pivot away from large EVs and toward hybrids and extended-range EVs that come with a gas generator is proof that sustainable powertrains are easy on paper, but hard in reality.
Tesla is perhaps the biggest beneficiary of Ford’s decision, especially as it will no longer have to deal with the sole pure EV pickup that outsold it from time to time: the F-150 Lightning.
Here’s why:
Reduced Competition in the Electric Pickup Segment
The F-150 Lightning was the Tesla Cybertruck’s primary and direct rival in the full-size electric pickup market in the United States. With Ford’s decision to end pure EV production of its best-selling truck’s electric version and shifting to hybrids/EREVs, the Cybertruck faces significantly less competition.
Credit: Tesla
This could drive more fleet and retail buyers toward the Cybertruck, especially those committed to fully electric vehicles without a gas generator backup.
Strengthened Market Leadership and Brand Perception in Pure EVs
Ford’s pullback from large EVs–citing unprofitability and lack of demand for EVs of that size–highlights the challenges legacy automakers face in scaling profitable battery-electric vehicles.
Tesla, as the established leader with efficient production and vertical integration, benefits from reinforced perception as the most viable and committed pure EV manufacturer.
Credit: Tesla
This can boost consumer confidence in Tesla’s long-term ecosystem over competitors retreating to hybrids. With Ford making this move, it is totally reasonable that some car buyers could be reluctant to buy from other legacy automakers.
Profitability is a key reason companies build cars; they’re businesses, and they’re there to make money.
However, Ford’s new strategy could plant a seed in the head of some who plan to buy from companies like General Motors, Stellantis, or others, who could have second thoughts. With this backtrack in EVs, other things, like less education on these specific vehicles to technicians, could make repairs more costly and tougher to schedule.
Potential Increases in Market Share for Large EVs
Interestingly, this could play right into the hands of Tesla fans who have been asking for the company to make a larger EV, specifically a full-size SUV.
Customers seeking large, high-capability electric trucks or SUVs could now look to Tesla for its Cybertruck or potentially a future vehicle release, which the company has hinted at on several occasions this year.
With Ford reallocating resources away from large pure EVs and taking a $19.5 billion charge, Tesla stands to capture a larger slice of the remaining demand in this segment without a major U.S. competitor aggressively pursuing it.
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Ford cancels all-electric F-150 Lightning, announces $19.5 billion in charges
“Rather than spending billions more on large EVs that now have no path to profitability, we are allocating that money into higher returning areas, more trucks and van hybrids, extended range electric vehicles, affordable EVs, and entirely new opportunities like energy storage.”
Ford is canceling the all-electric F-150 Lightning and also announced it would take a $19.5 billion charge as it aims to quickly restructure its strategy regarding electrification efforts, a massive blow for the Detroit-based company that was once one of the most gung-ho on transitioning to EVs.
The announcement comes as the writing on the wall seemed to get bolder and more identifiable. Ford was bleeding money in EVs and, although it had a lot of success with the all-electric Lightning, it is aiming to push its efforts elsewhere.
It will also restructure its entire strategy on EVs, and the Lightning is not the only vehicle getting the boot. The T3 pickup, a long-awaited vehicle that was developed in part of a skunkworks program, is also no longer in the company’s plans.
Instead of continuing on with its large EVs, it will now shift its focus to hybrids and “extended-range EVs,” which will have an onboard gasoline engine to increase traveling distance, according to the Wall Street Journal.
“Ford no longer plans to produce select larger electric vehicles where the business case has eroded due to lower-than-expected demand, high costs, and regulatory changes,” the company said in a statement.
🚨 Ford has announced it is discontinuing production of the F-150 Lightning, as it plans to report a charge of $19.5 billion in special items.
The Lightning will still be produced, but instead with a gas generator that will give it over 700 miles of range.
“Ford no longer… pic.twitter.com/ZttZ66SDHL
— TESLARATI (@Teslarati) December 15, 2025
While unfortunate, especially because the Lightning was a fantastic electric truck, Ford is ultimately a business, and a business needs to make money.
Ford has lost $13 billion on its EV business since 2023, and company executives are more than aware that they gave it plenty of time to flourish.
Andrew Frick, President of Ford, said:
“Rather than spending billions more on large EVs that now have no path to profitability, we are allocating that money into higher returning areas, more trucks and van hybrids, extended range electric vehicles, affordable EVs, and entirely new opportunities like energy storage.”
CEO Jim Farley also commented on the decision:
“Instead of plowing billions into the future knowing these large EVs will never make money, we are pivoting.”
Farley also said that the company now knows enough about the U.S. market “where we have a lot more certainty in this second inning.”
SpaceX employees, including its CEO Elon Musk, shaded American Airlines on social media this past weekend due to the company’s reported talks with Amazon’s Starlink rival, Leo.
Starlink has been adopted by several airlines, including United Airlines, Qatar Airways, Hawaiian Airlines, WestJet, Air France, airBaltic, and others. It has gained notoriety as an extremely solid, dependable, and reliable option for airline travel, as traditional options frequently cause users to lose connection to the internet.
Many airlines have made the switch, while others continue to mull the options available to them. American Airlines is one of them.
A report from Bloomberg indicates the airline is thinking of going with a Starlink rival owned by Amazon, called Leo. It was previously referred to as Project Kuiper.
American CEO Robert Isom said (via Bloomberg):
“While there’s Starlink, there are other low-Earth-orbit satellite opportunities that we can look at. We’re making sure that American is going to have what our customers need.”
Isom also said American has been in touch with Amazon about installing Leo on its aircraft, but he would not reveal the status of any discussions with the company.
The report caught the attention of Michael Nicolls, the Vice President of Starlink Engineering at SpaceX, who said:
“Only fly on airlines with good connectivity… and only one source of good connectivity at the moment…”
CEO Elon Musk replied to Nicolls by stating that American Airlines risks losing “a lot of customers if their connectivity solution fails.”
American Airlines will lose a lot of customers if their connectivity solution fails
— Elon Musk (@elonmusk) December 14, 2025
There are over 8,000 Starlink satellites in orbit currently, offering internet coverage in over 150 countries and territories globally. SpaceX expands its array of satellites nearly every week with launches from California and Florida, aiming to offer internet access to everyone across the globe.
Currently, the company is focusing on expanding into new markets, such as Africa and Asia.
Tesla stands to gain from Ford’s decision to ditch large EVs
Ford cancels all-electric F-150 Lightning, announces $19.5 billion in charges
