There are some people who think they’re smarter than the people who write the software for their Tesla. They even think they’re more alert than their car’s computer. Think again. The statistics show that you have about half as much chance of getting into an accident if you’re in Autopilot than if you aren’t using that feature of your Tesla.
Nobody can pay attention to every nearby car all the time. Nobody can even pay attention to what’s right in front of them all the time. People are human. Cars aren’t. Cars don’t get distracted by billboards, Maseratis, or accidents on the other side of a divided highway. Cars don’t text and drive or phone and drive. People get distracted by those things.
In an effort to prevent Teslas from getting in accidents that are the fault of the Tesla driver, Elon Musk has made autopilot a standard feature. You can use it on any road with clearly painted lines. It won’t make turns for you even when you have the GPS turned on and giving you directions, but it will be watching out for all the other cars nearby. Of course, that works only when you have autopilot turned on by clicking the gear shift lever down twice in a row. If you’re on a road without clearly pained lines, it won’t work, and it will give you an unpleasant sound if you try to use it on a local road without lines.
Lane Changing
On roads with lines, you can use Autopilot as long as you understand its limitations. Use it to change lanes by putting on the turn signal. The car will change lanes for you when it decides that it’s safe to change lanes. Here are the limitations for this. Autopilot won’t speed up past the limit you’ve set in order to change lanes. If there’s a spot in the next lane that you have to speed up for, you need to do that yourself. Sometimes, Autopilot will start to change lanes, but then it will bring you back to your current lane for no apparent reason. That sort of behavior will probably decrease with further software updates.
Uncommanded Actions
Regardless of what Elon Musk says, there are some uncommanded actions that the car makes in Autopilot, and the driver needs to be aware that they might happen. I use Autopilot nearly all the time. After all, that’s why I bought the Tesla instead of one of the less expensive electric cars. So what I’m about to say comes from personal experience,
Phantom braking happens every so often. So far, I haven’t been able to figure out what sets it off, but it happens at times. Make sure your car didn’t brake for a valid reason. If there’s no danger ahead, just press lightly on the gas pedal until the car stabilizes.
Uncommanded acceleration does happen at times. There’s one place near my house where I get uncommanded acceleration nearly every time I pass that way. Just press lightly on the brake, and the problem goes away.
Sharp Turns in the Road
Remember I said that Autopilot won’t make turns for you even when the GPS is telling you to make a turn and you put your turn signal on? Well, it also won’t follow a curve if it’s a very sharp curve. There are some sharp curves near my house where I need to take back control every single time I go on those roads or else my Tesla would hit the guard rail. So if you want to use Autopilot on local roads, you need to be aware of this issue and take control.
Autopilot quits driving
Any time you need to take control of your car, Autopilot quits driving. There will be a two-note sound that you’ll learn to recognize that tells you that you’re the only person driving. Sometimes, that happens even when you didn’t take control. The car may have just lost awareness of the road. Always be aware of that sound because if you ignore it, you may not realize that you’re the one driving until it’s too late.
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Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
Tesla has pioneered the use of single-piece castings for the front and rear sections of their vehicles, thanks to its innovative Gigapress process. Many automakers are now following suit, as this approach allows the crash structure to be integrated directly into the casting.
This makes the castings not only safer but also easier to manufacture in a single step, reducing costs and improving repairability. For example, replacing the entire rear frame of a Cybertruck is estimated to cost under $10,000 USD, with most of the expense coming from labor, according to estimates shared on X after high-speed rear collisions.
These insights come from Sandy Munro’s interview (posted below) with Lars Moravy, Tesla’s VP of Vehicle Engineering, highlighting how these advancements contribute to the improvements in Tesla’s latest vehicles, including the New Model Y.
However, with the new Model Y, Tesla has decided to go a different route and eliminated the front gigacast.
No Front Casting
Tesla’s factories aren’t equipped to produce both front and rear castings for the Model Y. Only Giga Texas and Giga Berlin used structural battery packs, but these were quickly phased out due to the underwhelming performance of the first-generation 4680 battery.
Tesla has gone back to building a common body across the globe, increasing part interchangeability and reducing supply chain complexity across the four factories that produce the Model Y. They’ve instead improved and reduced the number of unique parts up front to help simplify assembly and repair.
There is still potential for Tesla to switch back to using a front and rear casting - especially with their innovative unboxed assembly method. However, that will also require Tesla to begin using a structural battery pack again, which could potentially happen in the future with new battery technology.
Rear Casting Improvements
The rear casting has been completely redesigned, shedding 7 kg (15.4 lbs) and cutting machining time in half. Originally weighing around 67 kg (147 lbs), the new casting is now approximately 60 kg (132 lbs).
This 15% weight reduction improves both vehicle dynamics and range while also increasing the rear structure’s stiffness, reducing body flex during maneuvers.
Tesla leveraged its in-house fluid dynamics software to optimize the design, resulting in castings that resemble organic structures in some areas and flowing river patterns in others. Additionally, manufacturing efficiency has dramatically improved—the casting process, which originally took 180 seconds per part, has been reduced to just 75 seconds, a nearly 60% time reduction per unit.
Advancements in die-casting machines and cooling systems have allowed @Tesla to dramatically reduce cycle times and improve dimensional stability. pic.twitter.com/WB5ji67rvV
Tesla’s new casting method incorporates conformal cooling, which cools the die directly within the gigapress. Tesla has been refining the die-casting machines and collaborating with manufacturers to improve the gigapress process.
In 2023, Tesla patented a thermal control unit for the casting process. This system uses real-time temperature analysis and precise mixing of metal streams to optimize casting quality. SETI Park, which covers Tesla’s manufacturing patents on X, offers a great series for those interested in learning more.
The new system allows Tesla to control the flow of cooling liquid, precisely directing water to different parts of the die, cooling them at varying rates. This enables faster material flow and quicker cooling, improving both dimensional stability and the speed of removing the part from the press for the next stage.
With these new process improvements, Tesla now rolls out a new Model Y at Giga Berlin, Giga Texas, and Fremont every 43 seconds—an astounding achievement in auto manufacturing. Meanwhile, Giga Shanghai operates two Model Y lines, delivering a completed vehicle every 35 seconds.
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![A Look at the Tesla Cybertruck’s Crumple Zones [VIDEO]](https://www.notateslaapp.com/img/containers/article_images/cybertruck/cybertruck-crash-test.webp/e43ef2433bd6e44ae8db63421604a4fb/cybertruck-crash-test.jpg)
