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Tesla Model 3’s body structure is a strategic blend of aluminum and ultra high-strength steel
New photos from Tesla Model 3’s Body Repair Tech Note reveal a metal composition for the vehicle’s structure that strikes a perfect balance between world class safety and cost effectiveness.
One might recall Tesla CEO Elon Musk giving a tonque-in-cheek response about Model 3’s 5-star safety rating during a speech in Fremont, California. “The Volvo [S60] is arguably the second safest car in the world”, said Musk while alluding to the fact that Model 3 takes top honors for being the safest car in the world.
Photos posted to Twitter and shared on Reddit illustrate just how Tesla has been able to achieve a Model 3 body structure design that’s lightweight and has unparalleled strength at an entry level price point.
Looking at a front quarter exploded view of the Model 3 body, one can see the various compositions of steel the Tesla engineers used across the machine-stamped, multi-layer structure.
Tesla uses three different grades of steel, from mild steel used on the outer body structure where it’s designed to absorb initial impacts, and high-strength, to ultra high-strength used in the vehicle’s core. For instance, the A-pillar and B-pillar (noted in red on the graphic) is fabricated from ultra high-strength steel in order to provide maximum rollover protection. Model 3’s front frame rail is a composition between high-strength and ultra high-strength steel, and serves as the main support for the front “crumple zone”.
Tesla Model 3’s body repair manual notes that “Structural Pulling” is not allowed, meaning that any structural component that’s welded, weld-bonded, riveted, or rivet-bonded to the vehicle can not undergo a process wherein the straightening of structural parts are facilitated through a hydraulic pulling machine. Doing so would compromise the yield strength of the metals being used.
Also noted in the Model 3 structural diagram is the “underbelly” that serves as the main support for Model 3’s skateboard style battery pack, similar to what’s used in its older Model S and Model X siblings. The entire underside of the vehicle is fabricated from high-strength steel.
Side impact safety on the Model 3 is bolstered by a fully fortified closed steel structure in ultra high-strength steel. Looking at the crash test video showing a side-pole impact test performed on Tesla’s Model 3 and Volvo’s S60, one can easily see the level of deformity the Volvo has over the Model 3.
Watch a Tesla Model 3 vs. Volvo S60 side-pole impact test pic.twitter.com/dXBQkstrdo
— Tesla (@Tesla) July 29, 2017
Lastly, lightweight aluminum is introduced in areas of the body structure that are less susceptible to accidental impact such as the trunk floor and wheel wells. Using aluminum helps Model 3 maintain a relatively light curb weight of 3,549 lbs. for the standard version and 3,814 lbs. for the Long Range Model 3 with larger (and heavier) battery pack.
All in all, Tesla’s use of various steels and aluminum in Model 3’s body structure can be seen as a learning experience and first iteration towards even more affordable and higher volume production down the road – Model Y.
Tesla Cybercab rides are officially open to the public in Austin, Texas, as the company confirmed on Thursday following its launch event that the two-seater would be available in the company’s Robotaxi fleet.
Cybercab is Tesla’s first vehicle completely void of any manual controls. It has no steering wheel and no pedals, and it will utilize Tesla’s Full Self-Driving fleet to operate. The first rides have already happened, as those at the event were able to hail a Cybercab to any location within the company’s geofence in Austin.
Tesla’s $25K car is the Cybercab with no steering wheel or pedals
The addition of Cybercab to the public Robotaxi fleet is a major statement in Tesla’s trek to launch fully autonomous driving. For years, critics have complained about the need for drivers to continuously supervise the vehicle.
With Cybercab, there are no manual controls in the cockpit other than to control the seat, the center screen, and the climate. The vehicle is fully geared toward being a living room on wheels in a sense: equipped with Starlink V5 satellites, CEO Elon Musk said the vehicle would enable 4K live video, gaming, and other entertainment options during travel.
Cybercab is basically a super comfortable lounge on wheels with a great TV and epic sound https://t.co/X1aWKoJdJV
— Elon Musk (@elonmusk) September 3, 2026
Musk noted that Cybercab is “designed and built for maximally efficient autonomous operation.”
Tesla continues to push the envelope on autonomy, and over the next several months, the company could start selling Cybercab units to the public.
The company opened up a public interest form on its website to gauge demand, and many have already submitted requests to purchase a fleet of Cybercab units for their own personal ride-hailing side hustle.
The launch of Cybercab in this area marks a major accomplishment for Tesla, as it also announced that it has reached 1 million unsupervised autonomous miles since launching driverless rides on the Robotaxi fleet.
Things are moving along at a fine pace, and although we have waited for this for some time, the day has finally come when Tesla is offering self-driving rides of some kind to the public.
Tesla has quietly opened a public interest form for companies that want to buy fleets of its purpose-built Cybercab robotaxis, marking the first official channel for commercial purchases of the two-seat autonomous vehicle. The form went live on September 3, the same day Tesla hosted an invite-only Cybercab launch event in Austin, Texas.
Tesla titled the page “Help Us Build Our Robotaxi Network.” Applicants provide name, email, phone number, company name, and deployment region. They then select one or more categories: Cybercab fleet vehicle purchasing, mobility hubs and infrastructure, event collaboration, or other. Tesla says a representative will follow up with those who express commercial interest.
Tesla has introduced a new form that you can fill out if you are interested in purchasing a fleet of Cybercabs:
Form: https://t.co/Ut0yoiEyXD pic.twitter.com/uuaCXmksIO
— Sawyer Merritt (@SawyerMerritt) September 3, 2026
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Until now, the company had no public ordering path for the vehicle, which was first shown as a concept at the October 2024 “We, Robot” event.
The Cybercab is designed from the ground up for unsupervised operation. It has no steering wheel and no pedals.
Regulatory filings list a 48-kilowatt-hour battery, a single 219-horsepower front motor, a curb weight of 3,113 pounds, and an EPA-adjusted range near 290 to 300 miles. Tesla has already registered dozens of the vehicles with Texas authorities and has been testing them on public streets around Austin.
Tesla Cybercab sightings broaden well outside of Austin with autonomy in focus
The company’s existing Robotaxi service, which currently uses modified Model Y vehicles in parts of Texas and Florida, is expected to add Cybercabs as production ramps up at Gigafactory Texas.
The form signals that Tesla is preparing to treat the Cybercab as more than an in-house fleet asset. Investors and operators have discussed buying groups of the vehicles and placing them on Tesla’s ride-hailing network, with Tesla taking a platform fee. High-profile figures have publicly stated plans to acquire fleets if Tesla allows third-party ownership.
The new page gives those parties a direct way to register interest rather than waiting for a conventional configurator.
Whether the form leads quickly to firm purchase agreements remains unclear. Regulatory approval for widespread unsupervised operation still varies by state, and Tesla has not published pricing or delivery timelines for fleet customers. The company has previously discussed a target price near $25,000 to $30,000 per vehicle.
For now, the form is an early signal that Tesla wants partners to help scale the network rather than operate every Cybercab itself.
Pairing the launch of the Cybercab fleet form with the Austin event is no coincidence. Tesla is inviting businesses to participate in the next phase of its Robotaxi plan at the moment the production vehicle first appears in public.
Tesla has updated its Robotaxi app so riders can pick which vehicle they want before they book. The latest in-app screens now show two options side by side: the two-seat Cybercab and the four-seat Model Y.
A screenshot circulating Thursday shows the change in practice. In Austin, a rider could choose a gold Cybercab for two people or a Model Y for four. Tesla’s updated description calls Cybercab “our first purpose-built autonomous vehicle,” designed for safety, accessibility, and comfort, and says the lineup is available only through the Robotaxi app.
Tesla has updated their Robotaxi page in the App Store. You’ll be able to select if you want a Cybercab or Model Y Robotaxi.
“Our Robotaxi vehicle lineup now includes Cybercab, our first purpose-built autonomous vehicle. Designed for safety, accessibility and comfort, Cybercab… pic.twitter.com/Jff4klilDr
— Sawyer Merritt (@SawyerMerritt) September 3, 2026
The distinction is more than cosmetic, and it’s important to note that Robotaxi refers to the platform, while Cybercab refers to a vehicle.
Model Y Robotaxis have carried the service since it opened in Austin in mid-2025 and later expanded to Dallas, Houston, and parts of Florida. Those vehicles are converted production SUVs that still have steering wheels and pedals.
Cybercab is different. It has no driver controls, butterfly doors, a low seat height meant to work with wheelchairs, extra trunk space for assistive devices, and braille on the handles. Tesla has registered dozens of the two-seaters with Texas regulators in the days leading up to its September 3 Austin event.
Giving riders a choice lets Tesla match the vehicle to the trip. Most rides involve one or two people, which is where Cybercab is meant to be cheaper and more efficient to operate. Groups of three or four, or anyone who needs more space, can still request a Model Y.
The same app handles booking, payment, cabin settings, and, on Cybercab, features such as phone-based door opening and in-cabin voice controls.
The update does not mean every city suddenly has both cars available. Cybercab support is listed for Austin first, and the purpose-built fleet is still small compared with the existing Model Y roster. Even so, the app change marks a shift from a single-vehicle pilot to a mixed fleet.
Riders can now choose between the compact, purpose-built robotaxi and the familiar SUV that launched the service.
Tesla opens Cybercab rides to the public, with no steering wheel or pedals
Tesla hints its already prepping for Cybercab fleet orders
