Tesla Cybertruck lead engineer Wes Morrill detailed a minor April production change that enabled the model's IIHS Top Safety Pick+ rating, announced yesterday, with no impact on crash performance.
Following the Insurance Institute for Highway Safety's (IIHS) announcement on December 16 of the Top Safety Pick+ rating for 2025 Tesla Cybertruck models built after April, lead engineer Wes Morrill clarified the subtle manufacturing adjustment. "We made a minor change on the casting for manufacturability in April. Our internal testing shows no difference in crash result but IIHS only officially tested the latest version," Morrill posted on X on December 17.
This tweak improved production efficiency and scalability without affecting safety, contributing to 'good' ratings in small overlap front, moderate overlap front, side impact, roof strength, head restraints, front crash prevention (including pedestrian scenarios day/night), and headlights. It joins the Toyota Tundra crew cab as one of only two full-size pickups earning the award, outperforming the Ford F-150 and Ram 1500 under updated criteria.
The changes targeted the front underbody and footwell for better occupant protection. Secondary factors like seat belt reminders and LATCH were acceptable or marginal but did not impact the rating. While excelling in U.S. tests and complementing its NHTSA five-star score, the Cybertruck's design limits European market eligibility.