From Jesus Diaz writing for Fast Company, “Tesla’s Cybertruck has a serious problem that only a complete redesign can fix“:
The problem, according to Musk, is the bright metal construction and predominantly straight edges mean that even minor inconsistencies become glaringly obvious. To avoid this, he commanded unparalleled precision in the manufacturing process, stating in his email that “all parts for this vehicle, whether internal or from suppliers, need to be designed and built to sub 10 micron accuracy. That means all part dimensions need to be to the third decimal place in millimeters and tolerances need [to] be specified in single digit microns.” Drawing a comparison to everyday products known for their precision, Musk added, “If LEGO and soda cans, which are very low cost, can do this, so can we.”
The cybertruck is not made from LEGO blocks or soda cans. It’s just not feasible to have such tolerances on parts that are so big and non-uniform at production scale. I suspect we’ll continue to see the truck’s release date pushed back as each deadline comes whooshing by until they admit defeat and do a redesign.