Tesla’s Robotaxi event is rapidly coming up on 10/10, so let’s take a look at some of the cool concepts that we’ve seen.
We’ll start with what we know came from Tesla, and then we’ll let loose and take a look at what the community has come up with.
Tesla’s Concept Art & Previews
Not a Tesla App
The image above is Tesla’s official Robotaxi concept art – or well, as official as it gets. This is actually from Elon Musk’s biography, written by Walter Isaacson. We’re expecting a curvy two-seat vehicle – one that goes by the moniker of Cybercab.
Next up, we have this teaser image Tesla showed off in one of their videos on X. It’s unclear which part of the vehicle it is, but it seems like it could be either the front or rear aero spoiler – though we think it distinctly looks like the front.
Tesla
We’ve also got this interior shot of the Robotaxi that was shown off in an investor video back in May. Two wide, comfy seats, and one big screen in the center.
Dominic’s Cybercab Render
DominicBRNKMN
@DominicBRNKMN on X has once again outdone himself with this Cybercab concept he’s made – the butterfly swing doors look awesome, and it fits with the expected and distinct cyber styling we’ve already seen in Tesla’s previews.
The swing doors make it look easy to get in, and there seems to be plenty of space behind the seats for luggage. We’re a big fan of those wheels too – aero wheels are going to be an important component of the Cybercab – which will need to be efficient, cheap, and prevent debris from building up.
Sugar Design’s Render
Sugar Design
Sugar Design has made a few awesome renders (including of the Model Y Juniper) before – but let’s take a look at their older batch, and then their latest batch. Sugar Design’s concept render is based on the original image from Elon’s biography – and they’ve done an excellent job bringing it to life.
We think this may be pretty close to what the Robotaxi – Cybercab – will look like. It's got that distinct Cyber feeling to it and fits closely with what we expect the lines and curves to end up looking like.
You can check out the rest of Sugar Design’s renders on Instagram here – they do some fantastic work.
Teslaconomics Render
@Teslaconomics on X threw together a quick video render of what could be a falcon-wing Cybercab. If anything, it does feel a bit bigger than what we’re expecting – in fact, it looks like it’s Model X-sized. A cool-looking Cybercab like this would be awesome.
A Tesla Cybercab that is safer, cheaper, and no human driver is going to flip any existing ride-hailing companies upside down that thinks it’s not happening pic.twitter.com/vlFGzAB4I1
David – going by @dkrasniy on X, made some awesome-looking concept designs of the UI of the Robotaxi. We’re a really big fan of these– they integrate drop-off information on the right and provide the FSD preview on the left.
On top of that, it brings in a way to split your fair, preview your payment information, end the ride, and even a fancy little button to ask for help – powered by xAI’s Grok. Given the nods to Tesla’s design styles, David’s work here is pretty on the nose. We would be surprised if it doesn’t end up looking very similar to this.
Vitali Minin’s Concept Art
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@VitaliMinin
Vitali Minin - @VitaliMinin on X, also did up a cute-looking concept of the Robotaxi – we thought it would be neat to show something that’s not necessarily a render, but still an interesting-looking concept that didn’t get much attention. It fits with the cyber-style that we’re coming to expect, but we also like the sloped and curved rear that strikes a sharp profile.
These concepts are a great look at what we can expect Tesla to show off in less than two months at their Robotaxi event on October 10th.
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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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