Tesla will issue a software update to address issues the NHTSA has found
Not a Tesla App
The NHTSA has found several issues with Tesla's FSD Beta software that they found concerning. Tesla has agreed to voluntarily fix the issues outlined through a future FSD Beta update.
The recall notice posted to the NHTSA’s website says that Tesla’s FSD Beta software “allows a vehicle to exceed speed limits or travel through intersections in an unlawful or unpredictable manner [which] increases the risk of a crash.”
Tesla was notified of the issues identified by the NHTSA. The agency is primarily concerned about the “operational characteristics” of FSD Beta. During these scenarios, the NHTSA is concerned that FSD Beta “could potentially infringe upon local traffic laws or customs, which could increase the risk of a collision if the driver does not intervene.”
The Issues The NHTSA Found
The NHTSA outlined the four issues below that they would like Tesla to address. Some of these have been long-standing issues and owners may be happy to hear they're being addressed.
Traveling or turning through certain intersections during a stale yellow traffic light;
The perceived duration of the vehicle’s static position at certain intersections with a stop sign, particularly when the intersection is clear of any other road users;
Adjusting vehicle speed while traveling through certain variable speed zones, based on detected speed limit signage and/or the vehicle’s speed offset setting that is adjusted by the driver; and
Negotiating a lane change out of certain turn-only lanes to continue traveling straight.
Meetings with Tesla
Tesla met with the NHTSA a number of times over the last two weeks to discuss solutions. Despite disagreeing with the NHTSA’s analysis, they’ve issued a voluntary recall and will provide a software update to remedy the issues identified.
According to Protect My Car, “a voluntary recall happens when the manufacturer is made aware of an issue that poses a safety risk.” The manufacturer will typically issue them to remove their liability. “These recalls never expire and the free car repair will be made no matter how old the vehicle is, how many miles it has, or how many owners have had the vehicle,” per Protect My Car.
NHTSA Investigates Tesla
The NHTSA has been investigating Tesla over its Autopilot and Full Self-Driving Beta software. Last summer, the regulatory agency requested more information from Tesla about their “phantom braking” complaints. Shortly after, they upgraded the investigation to an “Engineering Analysis” after a few reports of vehicles with Autopilot engaged crashed into stopped emergency vehicles.
“The investigation will assess the technologies and methods used to monitor, assist, and enforce the driver’s engagement with the dynamic driving task during Autopilot operation,” the NHTSA said at the time.
Although not directly aimed at Tesla, the NHTSA also recently launched an investigation as to whether hybrid-electric and electric vehicles from 1997 to present should have external speakers installed for pedestrian safety. In July 2022, the NHTSA received a petition that urged them to require all hybrid-electric and electric vehicles to have external noisemakers installed.
“The petitioner asserts that hybrid and electric vehicles to which the standard does not apply should be found to contain a safety defect. In support of the petition, the petitioner includes findings contained in a bill introduced in the House of Representatives in 2009, the Pedestrian Safety Enhancement Act of 2009, H.R. 734, 111th CONG. (2009).”
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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.
![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)
