Tesla's highly-anticipated Cybertruck faces grave design problems, according to a leaked report recently published.

In May, German publication Handelsblatt obtained the "Tesla Files," a whistleblower's internal papers that revealed Tesla Cybertruck's issues.

One of these papers was an engineering study from January 25, 2022, which exposed serious problems with the "alpha" prototype Cybertruck, according to Wired, which evaluated the leaked report.

Despite Tesla CEO Elon Musk's praise of driving the most recent Cybertruck prototype in a tweet, the leaked study shows that the vehicle has problems with fundamental mechanical engineering issues. However, the report's findings are manageable for Tesla.

The electric vehicle manufacturer is anticipated to overcome these concerns, given its substantial financial resources. However, experts were surprised and concerned by the degree of the obstacles, believing that these are common concerns that should have been fixed throughout development.

Since 2020, Tesla has yet to introduce a new consumer car, falling behind its rivals, who have sped up their EV development to keep up with rising demand.

The Cybertruck's introduction is crucial to Tesla's image and momentum, but the firm also has to deploy new battery packs, extend Full Self-Driving software, and build an inexpensive EV. Analysts point out that Tesla's continual product delays highlight the necessity for new goods to support its growth story.

The Handelsblatt report also noted that the leaked internal dynamics and NVH (noise, vibration, and harshness) analysis compared the alpha Cybertruck's performance to CAD simulations and internal benchmarks. Sealing flaws caused leaks and cabin noise, according to the assessment.

Also noted were handling issues such as mid-speed abruptness and structural shaking. The braking performance also failed to hit Tesla's expectations, raising worries about the brake system's design and functioning.

Tesla Engineers Struggle Due To Cybertruck's Design

Former automotive executive Andy Palmer expressed amazement at the report's openness and emphasized that such frankness is unusual in the sector.

According to the report, engineers had difficulties because of the vehicle's distinctive shape and body sealing. It also showed that Cybertruck's braking mechanism was still a prototype, contrary to industry norms.

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A vehicle's ride and handling capabilities are assessed during kinematics and compliance (K&C) testing, which was done as part of the report. The alpha Cybertruck's K&C test results revealed a significant disparity compared to the planned targets, pointing out areas needing development.

 Tesla declined to comment on the leaked information and the Cybertruck's alleged technical issues.

A Tough Situation For Tesla

In February, footage of a Cybertruck prototype cautiously driving a curb near Tesla's Palo Alto worldwide engineering headquarters was reported by Autoevolution.

Discussions about possible issues started when observers saw that the prototype featured spot taillights rather than a light bar. Another video showed that during a drive in a parking lot in California, just the front left headlight was switched on.

In related news, Mustapha El Akkari, Tesla's former commodities group manager, joined Rivian as senior director for structures and materials, which was a blow to Tesla.

El Akkari was crucial in managing the supply chain for Tesla's Cybertruck and other vehicles, per Gizmodo. His departure and those of other Tesla executives hired by Rivian create further obstacles for the Tesla Cybertruck project.

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