Molds, Secondaries & Automation
For over 50 years, we’ve built our reputation on one core strength: delivering complex composite programs from concept to full production—faster, smarter, and at scale. Our work on the Tesla Cybertruck truck bed showcases not just what we build, but how we build it.
This program demanded more than a part—it required a fully integrated manufacturing ecosystem. In just 11 months, we designed, engineered, and launched a complete tooling and automation solution capable of supporting high-volume production.
The scope speaks for itself:
- 40 production molds
- 40 cooling fixtures
- 40 deflash fixtures
- 10 assembly fixtures
- 13 automated bond cells with robotic glue dispense and press systems
- 8 precision check fixtures
Every element was developed in-house as part of a coordinated strategy to ensure consistency, repeatability, and performance at scale.
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Case Study: Tesla Truck Box
Our strength lies in mastering the full composite lifecycle—tooling, automation, and production working as one seamless system. This allows us to move quickly without sacrificing precision, adapt designs without slowing momentum, and deliver production-ready solutions that meet the demands of next-generation BEV platforms.
Development of a New Compression Moulding Tool
The project focused on designing and building a compression tool to manufacture a lightweight truck box for a new Tesla platform using SMC material.
Material Innovation and Uncertainty
A newly developed lightweight SMC material with a custom blue-black resin (requiring additives) introduced unknowns in processing, flow behavior, weight, and overall moulding performance.
Design Challenges (Ribs & Wallstock Optimization)
Structural ribs needed to be small to prevent sink marks while maintaining strength, requiring extensive experimentation with varying wall thickness to balance aesthetics and performance.
Moulding Challenges (Warp, Flow, and Quality Issues)
Flat part geometry created high risk of warping and surface waves, while early trials revealed issues with material flow, fill consistency, and high scrap rates.
Iterative Testing and Process Advancement
Through multiple trials, material comparisons, and process adjustments, the team improved moulding performance, reduced defects, and successfully produced parts for pre-production validation and customer testing.
Assembly Equipment Innovation and Delivery
Secondary tooling – deflash, cooling, drilling or routing, punching, assembly, and bonding stations, are used for large body sub-assemblies, robotically machined openings in the products, apply adhesive, transfer and assemble components for final assembly at customer plant.
Get In Touch
Let us know how we can help you start your project.
(519) 737-1323
(519) 737-1747
office@lavaltool.net
4965 Concession Road 8, Tecumseh, ON N0R1K0
