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-Client Name

Tesla needed a solution for their robot. At Laval, we successfully completed the project from start to finish. 

Case Study: Tesla Truck Box

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.

Industrial metal parts produced in modern metalwork factory, copy space

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.Lorem ipsum dolor sit amet, consectetur adipiscing elit. Nullam ac nisl ullamcorper, tempus risus eu, pulvinar felis. Nunc et gravida nunc. 

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