How Tesla's Cybertruck Turns Car Engineering Norms Upside-Down - Motor Trend
'The plusses for a folded stainless steel, origami truck are compelling: no paint shop and no expensive tooling. No Godzilla-scale stamping machines stomping it with multiple strikes. Without all that, the capital and environmental costs of using stainless steel body panels are small. And big attractions for a company that's sensitive to both types of green—cash and environmentalism. Just groove the steel where it's supposed to fold (avoiding cracks) and bend it on simple, cheap machines (like I was actually doing last week with my garage vise!)
Brilliant … but prickly with trade-offs. Unlike the strength-to-weight efficiency of compound curves (feathery eggshells are the epitome), the flat-ish planes between the Cybertruck's simple bends require greater thickness to resist buckling compression loads or wrinkling oil-canning. Adding weight.
To counter this? Ditch the heavy, traditional, body-on-frame, and rethink the structure as weight-efficient trussed bridge in its simplest load-spreading configuration: a triangle set on its hypotenuse. One side is the Cybertruck's wedgy cab, the other, its tapered, sail-sided bed, their meeting point at the truck's tall peak resulting in a huge cross-sectional area for maximum stiffness.'