Ford copies the Cybertruck: 48V and gigacastings adopted

The Tesla Cybertruck has long been the target of mockery for its angular and polarizing design. Yet, behind its controversial aesthetics lies a true technological revolution that even traditional manufacturers can no longer ignore. Ford has just officially announced the adoption of two major innovations directly inspired by the Cybertruck: the 48V electrical architecture and structural gigacastings. These technologies will equip their future compact electric pickup aimed at the general public, with a target price of $30,000 and a launch planned for 2027. To achieve this transformation, Ford is investing no less than 5 billion dollars in its Universal EV platform. I have followed the Cybertruck’s evolution since its beginnings, and seeing Ford copy its innovations validates what many refused to admit: Tesla was once again right before everyone else.

Ford abandons the century-old 12V for the Cybertruck’s 48V system

The 12V electrical system has reigned over the automotive industry for over a century, a standard established in 1956 that has practically never been questioned. Tesla broke this tradition by introducing 48V on the Cybertruck in 2023, a silent revolution that went unnoticed by the general public but is radically transforming the architecture of electric vehicles.

Ford is now following this path for its Universal EV platform, and the numbers speak for themselves. The 48V architecture eliminates more than 1,220 meters of cables (or 4,000 feet) and saves 10 kg of weight compared to their first-generation electric SUVs. The system allows for a direct connection from the high-voltage battery, significantly reducing energy conversions and improving the vehicle’s overall energy efficiency.

Alan Clarke, former Tesla engineer now technical director of electric vehicles at Ford, states unequivocally that 48V is “the future of automotive.” When I explained the advantages of 48V after the Cybertruck’s launch, many dismissed me as a blind fanboy. Today, Ford validates this vision and proves that reduced wiring is not just a technical detail, but a major competitive advantage.

Tesla gigacastings revolutionize production at Ford

Gigacasting is a molding technique that allows for the production of large, single-piece aluminum structural parts, replacing dozens or even hundreds of traditionally welded components. Tesla popularized this method with the Model Y, then perfected it with the Cybertruck. Ford understood that this innovation could radically transform its manufacturing processes.

The numerical comparison is spectacular: the current gasoline-powered Ford Maverick requires 146 different structural components to assemble its chassis. Ford’s future electric pickup will use only 2 gigacasted parts (one front and one rear). This technological leap represents a considerable cost reduction and drastically accelerates assembly speed.

Beyond gigacastings, Ford is also inspired by the “unboxed” process developed by Tesla, which allows for non-linear assembly where multiple parts of the vehicle are built simultaneously before being assembled. These figures are impressive, and I must admit: going from 146 parts to 2 means completely rethinking automotive manufacturing. The Cybertruck has demonstrated its capabilities against traditional Ford pickups, and today Ford recognizes that superiority is not limited to performance, but extends to production methods.

A $30,000 electric pickup to counter the Chinese threat

The objective announced by Ford is clear: to offer a compact electric pickup for around $30,000 by 2027. This psychological price point is strategic for conquering the American market, where pickups account for more than 20% of total new vehicle sales. The Universal EV platform, which will benefit from a massive $5 billion investment, will serve as the basis for this new generation of vehicles.

Jim Farley, Ford’s CEO, calls this project a “bet” and a “Model T moment” for the company. This historical reference is not insignificant: it’s about democratizing the electric vehicle as Henry Ford democratized the automobile over a century ago. The strategic context is crucial, as Ford must respond to Chinese competition led by BYD and other manufacturers who already offer aggressively priced electric vehicles.

Ford publicly admits to having lost time on electric vehicles, and this transparency is refreshing. Ford has already compared its future pickups to the Cybertruck, proof that the Tesla reference is omnipresent in their strategic thinking. $30,000 for an electric pickup is exactly the psychological price to convince the American market. Ford has understood that copying Tesla is not a shame; it’s a necessity to stay in the race.

Alan Clarke, the ex-Tesla who guides Ford’s electric revolution

Alan Clarke perfectly embodies the phenomenon of skill transfer between Tesla and the traditional automotive industry. This former Tesla engineer, now technical director of electric vehicles at Ford, plays a key role in the adoption of the 48V architecture within the Dearborn manufacturer.

In his public statements, Clarke asserts that 48V represents “the future of automotive” and that “this is just the beginning” of the transformation. His profile illustrates a growing trend: several former Tesla employees are joining legacy manufacturers, bringing with them valuable expertise and a radically different culture of automotive innovation.

This talent transfer shows that Tesla is no longer just a competitor, but a true school that trains the engineers of tomorrow. The methods, processes, and philosophy developed at Tesla are gradually spreading throughout the industry, transforming how vehicles are designed and manufactured.

How the Cybertruck imposes its standards on the entire industry

The Cybertruck functions as a true technological laboratory rather than a simple commercial product. Its role extends far beyond unit sales: it tests and validates innovations that will then be adopted by the entire industry. Ford today, but who tomorrow?

The impact also extends to the supplier ecosystem, which must now adapt to new standards like 48V. This phenomenon recalls other Tesla innovations that gradually became standards:

• Superchargers, which led to the industry’s adoption of the NACS standard
• Gigacastings, now used by several manufacturers
• OTA (Over-The-Air) updates, now widespread

Even Ford F-350 drivers recognize the Cybertruck’s qualities, proving that technical validation eventually overcomes aesthetic prejudices. Those who criticized the design are now copying the technology, revealing where the true value lies.

I observe a constant in recent automotive history: Tesla faces criticism, then becomes the benchmark. The cycle repeats with the Cybertruck. What seemed eccentric in 2019 becomes the industrial norm in 2025, and automotive industry innovations continue to evolve at an unprecedented pace. Tesla’s technological leadership is not based on secrecy, but on the ability to innovate faster than others can copy. Ford has understood this, and this clarity could well save the century-old manufacturer in the electric transition.