Cutting/Bleeding edges on Cybertruck is side effect of using 1.4mm HFS instead of 3mm thickness?

[firsttruck]

The [Cybertruck] edges are not sharp. ...

Based on some owner reports, some regular people examining Cybertruck at Tesla service centers, some auto reviewers of Cybertruck, it looks like some of the Cybertrucks do have some exterior panels with sharp edges.

...
The panels are thicker than U.S. coins.

Not so with the currently shipping Cybertruck.

The original reveal Cybertruck was supposed to have 3mm thickness of cold-rolled 3xx stainless steel.

3mm would have been 50%-100% thicker than most officially issued U.S. coins.
Most U.S. coins are 1.52mm to 2mm except the dime which is 1.35.

https://en.wikipedia.org/wiki/Coins_of_the_United_States_dollar

Part of side effect of the shipped Cybertrucks's great (stronger) HFS is that 1. 8mm HFS door panels have better impact resistance than 3mm thickness of cold-rolled 3xx SS. The shipped Cybertruck HFS quater panels and HFS trim parts are even thinner being only 1.4mm

Most U.S. coins are made of a copper core & nickel cladding which are much softer than HFS (or cold-rolled 3xx SS) and the coins will not retain a sharp edge like HFS (or cold-rolled 3xx SS) can.

The panel edges should be chamfered, but I suppose some may not be perfect?

Most blades (other than cutting edge) of dinner tableware knives are 2mm-4mm thick. General kitchen knives are usually a thickness of about 0.100" - 0.140" (2.5mm - 3.5mm)

I am not sure if just chamfering/beveling will solve the entire issue with Cybertruck edges. The panels are so thin now (1.4mm) that chamfered/beveled edge might reduce some edge cut scenarios (scrapes) but introduce others (deeper punctures) because chamfering/beveling of 1.4mm HFS would now create almost a "real" knife like cutting edge.

Rounding of Cybertruck 1.4mm panels edges might be much better than chamfered/beveled but rounding still might not be enough with such thin (1.4mm) panels.

In the past there have been some vehicle recalls because of sharp edges causing injuries to people.

Also have read comments by some that Cybertruck owners just need to be careful. The situation is not just about the owners.
Most vehices are used in public and when parked are near people (including children) that may accidentally brush along side of vehicle or slip/trip and fall onto side of vehicle.


---------------------------------------------

Rounding off sharp edges with radius cutters
Good and accurate rounding of steel constructions according to EN 1090, ISO 12944, ISO 8501 or IMO PSPC is becoming more and more important in the metal working industry.
Beveltools (Velp, Netherlands)
https://beveltools.com/applications/rounding-metal/

---------------------------------------------

Determining sharpness of sheet metal edges
Metal fabricators need to be proactive about safety in
the design phase
By Victor Alexander Popp, PE
October 15, 2019
https://www.thefabricator.com/thefa...ep/determining-sharpness-of-sheet-metal-edges

....
When sharpness is not desirable, you should follow a hierarchy for making safe products, as defined om ISO 12100.2010:
1. Design out hazards.
2. If that can't be done, protect against them.
3. If that isn't possible, warn against them (in manual & product labels).

If a product liability lawsuit ensues, you need to be able to convince a jury that the consumer ignored warnings or misused pro

.....
Standards and Testing Methods

.....
* .016 inch length = .41 mm

---------------------------------------------

Ford recalling more than 300,000 Explorers over sharp seats
Yes, people have injured their hands
Reuters
Sep 13th 2019
https://www.autoblog.com/2019/09/13/ford-explorer-recall-sharp-seat-edge/

Ford recalls some vehicles due to sharp seat frame edge
More than 23,000 2017 Ford Explorer vehicles are being recalled in Canada
The Associated Press · Posted: Sep 13, 2019
https://www.cbc.ca/news/business/2017-ford-explorer-vehicle-recall-1.5282283

---------------------------------------------

Hyundai recalling over 91,000 Sonata sedans due to... sharp chrome door handles?!
Chris Shunk
May 26th 2009
https://www.autoblog.com/2009/05/26/hyundai-recalling-over-91-000-sonata-sedans-due-to-sharp-chro/

---------------------------------------------

Recall by Volkswagen Canada & Volkswagen Australia
2013-2019 Volkswagen Golf / GTi / Golf R / Mk7 / Alltrack
The trim around the gear select lever had a sharp edge that resulted in several customers receiving cuts or gouges to hand/fingers.
This part was replaced. Volkswagen

---------------------------------------------

Rigid Lifelines fall protection systems | Leading and Sharp Edges in Fall Protection
Leading and sharp edges are a huge threat in the fall protection industry. Not only do leading and sharp edges present unique risks, but they also require special products. Using standard personal fall arrest products can have catastrophic results for employees working on leading and sharp edges.

OSHA defines a leading edge as “a walking/working surface (horizontal and vertical surface) with an unprotected side or edge which is . . . above a lower level.” Falling greater than the trigger height (leading edge) is often accompanied by a sharp edge. A sharp edge is straightforward, meaning an edge that has the ability to cut or damage traditional lanyards. Sharp edges can be anywhere and should be identified during a fall hazard analysis.
** The smaller the edge radius, the sharper the edge is. For this reason employees should know where sharp edges are and how to avoid them. **
March 20, 2015
https://www.rigidlifelines.com/blog/what-you-should-know-about-leading-and-sharp-edges/

---------------------------------------------


How to Smooth Sheet Metal Edges
By aerguvan
Post date 12/11/2022
https://ems-metalworking.com/how-to-smooth-sheet-metal-edges/

.....
7. Edge Rounding Machines: Edge rounding machines are specialized machines designed to create a smooth, rounded profile on the edges of sheet metal components. These machines offer precise control and consistency, particularly for large-scale production or when a specific edge radius is required.


---------------------------------------------


How much edge rounding does sheet metal need?
09/10/2020
ARKU Magazine
https://www.arku.com/en/magazine/edgerounding-sheetmetal

---------------------------------------------

Choosing the Best Chef Knife Size-Length, width and thickness
1/8" (3.2 mm) is a good starting point for 8'' chef's knife and 3/32'' (2.4mm) or thicker is great for kitchen knives.
https://www.vosteed.com/blogs/guides/choosing-the-best-chef-knife-size-length-width-and-thickness

---------------------------------------------


Flatware Buying Guide: Thickness and Weight Standards
Although there is no real universal standard, flatware is generally categorized in the following categories. The dinner fork generally sets the standard for a pattern. Typically the place spoon and the salad fork will be one gauge lighter and the teaspoon will be one or two steps down from the dinner fork. Here is our take on what that means in terms of thickness or weight:
https://libertytabletop.com/flatware-buying-guide/thickness-and-weight-standards/

---------------------------------------------

Protocase electronic enclosures material option - Stainless Steel
Same stiffness advantage of steel yet even higher strength.
Non-painted Stainless is 'passivated' using Citric Acid to remove any iron contamination that may show up as rust spots.
https://www.protocase.com/products/materials-components-finishes/materials/stainless-steel.php

---------------------------------------------

Sponsored

 

[CyberGus]

Making a safer Cybertruck is a laudable goal.

However...

We all just accept that ICE vehicles have a searing-hot tailpipe that any kid could run up and grab, or leak antifreeze that will kill animals that drink it, etc.

Don't wanna be cut by a Cybertruck? Go feel up your own damn car

 

[carsly]

Making a safer Cybertruck is a laudable goal.

However...

We all just accept that ICE vehicles have a searing-hot tailpipe that any kid could run up and grab, or leak antifreeze that will kill animals that drink it, etc.

Don't wanna be cut by a Cybertruck? Go feel up your own damn car

And crazy-hot hoods after running for a few hours and let's not even address the spinning fans in front of every radiator and the ones which leak oil onto pavement creating a slip hazard every time it rains.

I'd argue BEV's are far safer for people bumping into vehicles in parking lots (which they shouldn't be doing anyway) than any ICE vehicles, Cybertruck included.

One side note, HFS stainless left in the sun gets incredibly hot. I haven't had an opportunity to measure surface temps yet but there is a massive difference in temps between the sunny side stainless and the shady side stainless steel. Is it better or worse than a black ICE vehicle? Who knows. Just don't touch either one!

 

[ideaXfactory]

My best guess is that the edges are rounded properly in production, but then because of additional scratches, or discoloration, or some other reason, it is sanded/polished again. This could happen late in the stage of manufacture, or at the SC, or by the owner, or by someone doing a mod.

Additional sanding/finishing can easily create a new sharp edge. Obviously if checked for and caught, edges can easily be slightly rounded again.

 

[GuyV]

Based on some owner reports, some regular people examining Cybertruck at Tesla service centers, some auto reviewers of Cybertruck, it looks like some of the Cybertrucks do have some exterior panels with sharp edges.



Not so with the currently shipping Cybertruck.

The original reveal Cybertruck was supposed to have 3mm thickness of cold-rolled 3xx stainless steel.

3mm would have been 50%-100% thicker than most officially issued U.S. coins.
Most U.S. coins are 1.52mm to 2mm except the dime which is 1.35.

https://en.wikipedia.org/wiki/Coins_of_the_United_States_dollar

Part of side effect of the shipped Cybertrucks's great (stronger) HFS is that 1. 8mm HFS door panels have better impact resistance than 3mm thickness of cold-rolled 3xx SS. The shipped Cybertruck HFS quater panels and HFS trim parts are even thinner being only 1.4mm

Most U.S. coins are made of a copper core & nickel cladding which are much softer than HFS (or cold-rolled 3xx SS) and the coins will not retain a sharp edge like HFS (or cold-rolled 3xx SS) can.



Most blades (other than cutting edge) of dinner tableware knives are 2mm-4mm thick. General kitchen knives are usually a thickness of about 0.100" - 0.140" (2.5mm - 3.5mm)

I am not sure if just chamfering/beveling will solve the entire issue with Cybertruck edges. The panels are so thin now (1.4mm) that chamfered/beveled edge might reduce some edge cut scenarios (scrapes) but introduce others (deeper punctures) because chamfering/beveling of 1.4mm HFS would now create almost a "real" knife like cutting edge.

Rounding of Cybertruck 1.4mm panels edges might be much better than chamfered/beveled but rounding still might not be enough with such thin (1.4mm) panels.

In the past there have been some vehicle recalls because of sharp edges causing injuries to people.

Also have read comments by some that Cybertruck owners just need to be careful. The situation is not just about the owners.
Most vehices are used in public and when parked are near people (including children) that may accidentally brush along side of vehicle or slip/trip and fall onto side of vehicle.


---------------------------------------------

Rounding off sharp edges with radius cutters
Good and accurate rounding of steel constructions according to EN 1090, ISO 12944, ISO 8501 or IMO PSPC is becoming more and more important in the metal working industry.
Beveltools (Velp, Netherlands)
https://beveltools.com/applications/rounding-metal/

---------------------------------------------

Determining sharpness of sheet metal edges
Metal fabricators need to be proactive about safety in
the design phase
By Victor Alexander Popp, PE
October 15, 2019
https://www.thefabricator.com/thefa...ep/determining-sharpness-of-sheet-metal-edges

....
When sharpness is not desirable, you should follow a hierarchy for making safe products, as defined om ISO 12100.2010:
1. Design out hazards.
2. If that can't be done, protect against them.
3. If that isn't possible, warn against them (in manual & product labels).

If a product liability lawsuit ensues, you need to be able to convince a jury that the consumer ignored warnings or misused pro

.....
Standards and Testing Methods

.....
* .016 inch length = .41 mm

---------------------------------------------

Ford recalling more than 300,000 Explorers over sharp seats
Yes, people have injured their hands
Reuters
Sep 13th 2019
https://www.autoblog.com/2019/09/13/ford-explorer-recall-sharp-seat-edge/

Ford recalls some vehicles due to sharp seat frame edge
More than 23,000 2017 Ford Explorer vehicles are being recalled in Canada
The Associated Press · Posted: Sep 13, 2019
https://www.cbc.ca/news/business/2017-ford-explorer-vehicle-recall-1.5282283

---------------------------------------------

Hyundai recalling over 91,000 Sonata sedans due to... sharp chrome door handles?!
Chris Shunk
May 26th 2009
https://www.autoblog.com/2009/05/26/hyundai-recalling-over-91-000-sonata-sedans-due-to-sharp-chro/

---------------------------------------------

Recall by Volkswagen Canada & Volkswagen Australia
2013-2019 Volkswagen Golf / GTi / Golf R / Mk7 / Alltrack
The trim around the gear select lever had a sharp edge that resulted in several customers receiving cuts or gouges to hand/fingers.
This part was replaced. Volkswagen

---------------------------------------------

Rigid Lifelines fall protection systems | Leading and Sharp Edges in Fall Protection
Leading and sharp edges are a huge threat in the fall protection industry. Not only do leading and sharp edges present unique risks, but they also require special products. Using standard personal fall arrest products can have catastrophic results for employees working on leading and sharp edges.

OSHA defines a leading edge as “a walking/working surface (horizontal and vertical surface) with an unprotected side or edge which is . . . above a lower level.” Falling greater than the trigger height (leading edge) is often accompanied by a sharp edge. A sharp edge is straightforward, meaning an edge that has the ability to cut or damage traditional lanyards. Sharp edges can be anywhere and should be identified during a fall hazard analysis.
** The smaller the edge radius, the sharper the edge is. For this reason employees should know where sharp edges are and how to avoid them. **
March 20, 2015
https://www.rigidlifelines.com/blog/what-you-should-know-about-leading-and-sharp-edges/

---------------------------------------------


How to Smooth Sheet Metal Edges
By aerguvan
Post date 12/11/2022
https://ems-metalworking.com/how-to-smooth-sheet-metal-edges/

.....
7. Edge Rounding Machines: Edge rounding machines are specialized machines designed to create a smooth, rounded profile on the edges of sheet metal components. These machines offer precise control and consistency, particularly for large-scale production or when a specific edge radius is required.


---------------------------------------------


How much edge rounding does sheet metal need?
09/10/2020
ARKU Magazine
https://www.arku.com/en/magazine/edgerounding-sheetmetal

---------------------------------------------

Choosing the Best Chef Knife Size-Length, width and thickness
1/8" (3.2 mm) is a good starting point for 8'' chef's knife and 3/32'' (2.4mm) or thicker is great for kitchen knives.
https://www.vosteed.com/blogs/guides/choosing-the-best-chef-knife-size-length-width-and-thickness

---------------------------------------------


Flatware Buying Guide: Thickness and Weight Standards
Although there is no real universal standard, flatware is generally categorized in the following categories. The dinner fork generally sets the standard for a pattern. Typically the place spoon and the salad fork will be one gauge lighter and the teaspoon will be one or two steps down from the dinner fork. Here is our take on what that means in terms of thickness or weight:
https://libertytabletop.com/flatware-buying-guide/thickness-and-weight-standards/

---------------------------------------------

Protocase electronic enclosures material option - Stainless Steel
Same stiffness advantage of steel yet even higher strength.
Non-painted Stainless is 'passivated' using Citric Acid to remove any iron contamination that may show up as rust spots.
https://www.protocase.com/products/materials-components-finishes/materials/stainless-steel.php

---------------------------------------------

Gee, that's a whole lot of references! Did you use AI? But none of them actually say the Cybertruck panel edges are sharp. ?

 

[electricAK]

There are plenty of vehicles with sharp corners on door panels. Nobody cares.

 

[txtravwill]

I'd say the edges are definitely not razor sharp but if you slide anything on long then, they are rough and will slice ya open. Have to be careful and while many for us are, when MASS produced there are going to be a lot more I juries I can predict.

 

[GuyV]

I'd say the edges are definitely not razor sharp but if you slide anything on long then, they are rough and will slice ya open. Have to be careful and while many for us are, when MASS produced there are going to be a lot more I juries I can predict.

Mine are not rough at all. If yours are perhaps you should contact Tesla for correction.

 

[CyberGus]

FYI, I just rubbed the rear edge of the stainless by the tailgate. I pressed fairly hard but did not suffer any laceration.

If a graze could cause a deep gash, I posit that the edge was incorrectly finished. It’s a thin piece of metal, but it is not “sharp”.

 

[tmeyer3]

I posit

 

[firsttruck]

Making a safer Cybertruck is a laudable goal.

However...

We all just accept that ICE vehicles have a searing-hot tailpipe that any kid could run up and grab,
....

I could not "find run up and grab" but there definitely are regulations to try to reduce burn incidents.


-------------------------------


2022 Georgia Code
Title 40 - Motor Vehicles and Traffic
Chapter 8 - Equipment and Inspection of Motor Vehicles
Article 1 - Equipment Generally
Part 4 - Horns, Exhaust Systems, Mirrors, Windshields, Tires, Safety Belts, Energy Absorption Systems
§ 40-8-71. Exhaust System; Prevention of Noise, Smoke, and Fumes
Universal Citation: GA Code § 40-8-71 (2022)
https://law.justia.com/codes/georgia/2022/title-40/chapter-8/article-1/part-4/section-40-8-71/

.....
There shall be no part of the exhaust system
... any exposed stack so located that any individual entering or leaving the vehicle may be burned.


------------------------------------

State Regulations Utah Administrative Code Topic - Public Safety Title R714 - Highway Patrol Utah Admin. Code R714-162 - Equipment Standards for Heavy Motor Vehicle, Trailer and Bus Safety Inspections Utah Admin. Code R714-162-14 - Exhaust System
Utah Admin. Code R714-162-14 - Exhaust System
https://www.law.cornell.edu/regulations/utah/Utah-Admin-Code-R714-162-14

.....
(i) issue a rejection inspection certificate when:
....
(H) exhaust stacks are located in a position in which an individual may be burned upon entering or leaving the vehicle


------------------------------------


State Regulations Missouri Code of State Regulations Title 11 - DEPARTMENT OF PUBLIC SAFETY Division 50 - Missouri State Highway Patrol Chapter 2 - Motor Vehicle Inspection 11 CSR 50-2.260 - Exhaust System
11 CSR 50-2.260 - Exhaust System
https://www.law.cornell.edu/regulations/missouri/11-CSR-50-2-260

.....
(3) Reject vehicle if:
.....
(E) Tailpipe is located so that a person may be burned on entering or leaving passenger compartment;


------------------------------------

Wisconsin Legislature: Trans 305.20 - Chapter Trans 305 - STANDARDS FOR VEHICLE EQUIPMENT
https://docs.legis.wisconsin.gov/code/admin_code/trans/305/ii/20

.....
Subchapter II — Automobiles, Motor Homes and Light Trucks

.....
Trans 305.20 Exhaust and air pollution control systems.
....
(3) Every exhaust system located so as to be hazardous to a person outside the vehicle or to a person entering or leaving a vehicle shall be protected in order to prevent such person from being burned or otherwise injured. The exhaust system location shall be considered hazardous if it extends beyond the body line for those systems where the exhaust pipes are on or extend to the side of the vehicle. A system where the exhaust pipes extend upward along the side or rear of the body shall also be protected in order to prevent persons from being burned or otherwise injured.


------------------------------------

 

[Deleted member 17810]

No, it's a result of them not post processing the panels after cutting them.

 

[Sirfun]

I got to spend some time looking over a new Cybertruck in a driveway yesterday, and being a retired sheet metal worker the much thinner stainless steel, and the raw edges were mind blowing. First, I was surprised by design choices with raw edges pointing forward into the wind between the sides and the front. Plus the hood doesn't overlap the sides. Both of these choices would allow more water intrusion and it's skinny raw stainless steel. Normally when I would make things out of 18ga stainless I would always at a minimum use rounding tools to finish them, but these protruding edges really look like they should have been hemmed to make them way stronger, and smooth to the touch. One positive out of seeing the new (paper plate) Cybertruck, was that the panels looked WAY better than the one I saw in December at a service center. They didn't have hardly any waviness, unlike the horrible one I saw in Dec.

This thinner sheet metal is just one more issue I had with all the hype we were given over the years. 3mm stainless would work way better with all those raw metal edges.

 

[ARMANDO PADILLA]

not only are the edges raw but you have a bad pinch situation heres an illustration i made to show what i mean.

 

[Jack27]

Is this available in cliff notes ?

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