Same. Initially I was optimistic about the Cybertruck because I though “flat metal panels and no paint is going to make both manufacturing and repairs so much easier and cheaper”.
Same. Initially I was optimistic about the Cybertruck because I though “flat metal panels and no paint is going to make both manufacturing and repairs so much easier and cheaper”.
Paint has been well studied. We know how to do it really cheap and automated these days. Cheap is relative. I'm sure that we're talking tens of millions of dollars to get all the equipment needed. But on a scale of factory and for how long it will last, that's cheap.
Flat metal is more expensive than curved metal. Curved metal, you design the curves to help support the stress points: you can get by with thinner sheets. Flat metal requires thicker heavier more expensive sheets of sheet metal in order to be strong enough.
Curved metal also lets you design the whole thing to be more aerodynamic. which is an important consideration even with something as un-aerodynamic as a truck.
> I'm sure that we're talking tens of millions of dollars to get all the equipment needed.
Painting cars really is a hugely optimised process that materially affects performance characteristics such as weight.
Its very difficult to appreciate just how many cars are made worldwide wide, but just think if a completely optimised fully robot optimised line cost a billion dollars, in only needs to process a few million cars to fully pay itself off. Just look at how much a “paint option” costs. Enough people paying for a premium colour would completely pay for the entire production painting line.
Painting cars is also a process that scales. If you want to do a great job on one car everything you need can be had for less than $3000 (inflatable spray booth, large air compressor, a paint gun, and lots of sand paper). A good job can be done for less (a cheap air compressor and paint outside can still get good results), and most people who want to paint a car already have most of the tools so the cost goes down. The above setup will also handle a small auto body shop that is painting a couple cars per month, and you can upgrade equipment as needed (I'd start with a spray building instead of an inflatable booth).
At the scale of Tesla the millions of dollars on a fully automated setup is cheap because amortize the cost of so many cars
Painting actually introduces some scaling issues in manufacturing. Any painting step prevents you from haphazardly mixing all the parts produced on a line. Most vehicles will have multiple lines that eventually converge across multiple suppliers. Painting forces you to either coordinate the production of each individual component so that they're all painted the correct color during final assembly (which becomes difficult if any parts fail QA), or buffer painted parts in a giant warehouse. There's other advantages to the warehouse, but I wouldn't call it cheap.
Very common to use a mix of both strategies in practice.
They built that truck backwards and upside down. The single-piece forged aluminum frame was basically impossible to repair and brittle. Typical truck frames flex, they're part of the suspension. For small accidents, the frame can be bent back. The CT would just crack, requiring extensive aluminum welding to fix which is waay harder than welding a steel frame.
I thought this is not relevant tbh.
Either you have a modern expensive car and insurance which knows how to handle it properly, or it doesn't matter anymore and you got to a cheap car doctor.
There were no flat panels. That was a sales pitch. In reality, a slight curve to a panel adds so much strength that it can be made considerably lighter/cheaper than a flat panel of sufficient strength. Flat panels also tend to dent inwards very easily, which is not a good look for a car. Then there is the issue of thermal expansion. A pre-bent bit of metal will expand in a predictable way. A dead-flat panel could buckle in multiple unexpected ways.
I had a jeep wrangler once. The window was "flat" but not if you looked at its reflection. There was an almost imperceptible but complex curve, no doubt for strength.
Repair will be easier and cheaper? :D
As the DeLorean community will tell you, repairing unfinished stainless steel to aesthetically pleasing levels is almost impossible.
Take a piece of tinfoil, crumple it, then try to uncrumple it to its factory finish.
Repairing painted bodywork is easy and cheap: hammer it to get a rough shape, apply fillers, then paint & polish to factory finish. Simple as.
how you repair steel panel and also make it look nice ?
...you don't. You replace it in whole. You can't use filler to mask small dents and paint over it, if you want it to look as before, you have to pretty much replace it.
A steel panel would we repairable with the same tools a curved panel is. You can pull out dents without filler - filler is for fiberglass.