Tesla’s Cybertruck has received an underbody redesign that appeared to be a carbon-fiber upgrade, but the company has now clarified that the new panels are made from self-reinforcing polypropylene. The material change makes the panels lighter, more impact-resistant and less expensive to produce than the stamped aluminum shields they replace.
Tesla Explains the Cybertruck Aero Shield Redesign
Last month, brand-new Cybertrucks began appearing with dark underbody panels instead of the silver aluminum shields used previously. The change quickly fueled speculation that Tesla had switched to carbon fiber.
The panels appeared to have the look of carbon fiber, and Cybertruck Lead Engineer Wes Morrill described the new material as lighter, tougher and cheaper than stamped aluminum. Tesla has now clarified that carbon fiber was not involved.
According to Morrill, the redesigned panels use self-reinforcing polypropylene. Tesla stretches polypropylene into fibers and then laminates the material into shape, producing a structure that is stronger than regular plastic while remaining lighter than aluminum.
Tesla says the new material improves on the previous stamped aluminum design in several key areas. It is lighter, handles impacts better and costs less to manufacture.
New Material Also Improves Aerodynamics
The material change gave Tesla engineers more flexibility to alter the shape of the Cybertruck’s aero shield. They were able to adjust the geometry around mounting bolts and panel edges, areas that were more difficult to modify when the shield was made from stamped aluminum.
Those changes help smooth airflow beneath the Cybertruck and reduce aerodynamic drag. As a result, the redesign is more than a simple material replacement: The new panel is lighter, tougher, easier to manufacture and helps the truck move through the air more efficiently.
Tesla Continues Updating the Cybertruck
Morrill also revealed that the aero shield is only one of many changes Tesla has made to the Cybertruck since production began.
Looking at the latest trucks coming out of Gigafactory Texas, Morrill said some updates are intended to improve functionality, while others focus on cost, reliability, service or making the vehicle easier to build.
Morrill described the Cybertruck as “a living thing,” emphasizing that production is not the end of its development and that the truck continues to evolve after launch.
He did not reveal what changes Tesla may make next, leaving the possibility of additional hardware, software or both without providing specific details.
Cybertruck Prices Have Increased
While Tesla continues making changes to the Cybertruck, the vehicle’s price has not received a quiet improvement. The Cybertruck Dual Motor AWD now starts at $74,990, which is $5,000 more than before.
The Premium AWD also increased by $5,000, bringing its starting price to $84,990. The Cyberbeast remains priced at $99,990.
For buyers considering the entry-level Cybertruck, the higher price comes as Tesla continues making changes to the truck behind the scenes, including the newly redesigned aero shield.
