Carbon door hook trim
Tesla Model 3 - Y

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Model Sport, the company that promotes a method of producing carbon parts, but which one? Composite material: its determination? The true meaning of a carbon element?

Here we will see these fundamentals in three parts:
• It is eminent to look once and for all at what carbon actually is
• The different vision of the Model Sport brand in the development of its carbon parts
• What you can find

By finishing your reading, you will be able to obtain a real carbon element knowingly.

Composite material: what is its definition?

By designation, what is called composite material represents the assembly of two components together, which does not mix, but which produces an object more resistant to shocks/impacts/torsions/flexions than if they are used independently l each other.

Typically you can take reinforced concrete as an example.

Carbon or Texalium, what can you find for your electric?

In fact, there are many categories of carbon and many ways to work with it.

This is the proper term 'carbon fiber composite' to be used, although in most cases it is referred to as 'the carbon', it is important to know in the world of stratification it is this designation that is used.

3K twill in 200gr, the function of carbon fabric:

Let's start our development with the most popular of all: 3K carbon twill. Each way of weaving carbon has a specific name, that of twill is one of them.

The figure above is just there to give you an example of this.

Twill is the most widely used of braids and for good reason, one of them is its maneuverability allowing it to adapt appreciably in a mold with pronounced shapes and curvatures. There are even more accentuated details such as the 3/1, 2/2 and 4/4 criss-crossing, but this is not a technical development, but more of a brief explanation.

The sign annotated "3K" has as its definition the total number of filaments which constitutes a single carbon frame, in total unit: 3000 filaments.

To give you a fairly representative order of magnitude, the thickness of a strand of carbon is 1/20 of that of a hair.

So there are several allocations, the most common are 1K, 3K, 6K, 12K. The Tesla community, as well as other automotive sectors and brands, particularly use 3K. The term “200 gr/m²” suggests that 1 m² of carbon sheet, before treatments, weighs 200 grams.

Remember: 3K twill weighing 200 grams per square meter is widely used in the Tesla community. Not for its mechanical properties; but rather for its aesthetic configuration.

Forged carbon, let's see what this name describes:

We may think that this name of "forged carbon" is commercial or overused, however, its manufacturing process requires equipment and implementation techniques that are already a few years old and above all, which really make it more efficient.

To make it, you first have to cut the carbon into small strips and sprinkle it more or less evenly into the mould. It is now necessary to put the resin and tighten the positive and negative master of the mold until they are under compression.

The mold temperature is also increased during this phase. Why use this manufacturing logic? Quite simply to allow more carbon to be condensed for less resin. All the excess resin is ejected during the pressurization phase.

So you get a stiffer and lighter part. We must go back to the 80s to discover the first uses of forged carbon in the warhead manufacturing industry, however this manufacturing logic was noticed only from its use at the Lamborghini brand.

Let's now highlight the most unknown of all, which is Texalium

Very often it is likened to carbon, but that has nothing to do with it. The Texalium is totally different in substance and form.

It is in order to acquire the desired appearance that this material is actually fiberglass loaded with aluminum, the resin or the varnish will then be nuanced to give it a specific color.

Its mechanical properties are below the usual glass fabric (itself below the carbon fabric) and its use is purely for aesthetics. Much better known in the United States, he is just beginning to make himself known in France.

Carbon: what is it?

For this part, we will simply give you examples of what is possible to produce with carbon fiber.

If you are interested in a product or part, Model Sport can provide you with a quote.

What is the resistance of carbon?

This question deserves once and for all an appropriate answer. In truth, it is more accurate to wonder about the possible comparisons with other materials.

To give you an idea: an aluminum alloy that has a physical volume equal to a carbon part will be less durable than the latter, all constraints combined.

However, the term "resistant" deserves some clarification. Even if carbon is less resistant to impacts, it has surprising qualities when twisting or bending. It is for this justification that for Tesla automobiles it is so common to produce ultra-thin carbon inserts that stick to existing parts without suspicion of breakage.

For model 3 or Y, the dashboard cover insert is a very good example. Only two layers of carbon fabric are used to produce a 1.40m long piece, which will be sent to France or other border countries without any problem.

Why is carbon fiber so expensive?

What is essential to explain in order to understand the price of carbon, it is necessary to return to the operation of production of it.

A single carbon fiber already requires quite a remarkable amount of technique. To roughly define the stages of manufacturing a single carbon fiber, you have to start your work with a synthetic fiber called polyacrylonitrile, this one will be put under oxidation then then logically calcined to offer us this inimitable carbon fiber. .

The awareness of more and more carbon fiber production industries gives rise to certain projects, totally directed with the aim of developing it using the least possible chemical products.

The application of bio-sourced materials is fashionable and even more and more necessary to meet certain environmental criteria put in place. The goal: the elimination of chemicals, but also a division of the price. The material required to weave the carbon fibers is also more than substantial, in terms of investment and space.

30 euros per square meter is the average value, at the time of writing, that you will be able to find a 200gr/m² 3K twill carbon sheet.

Added to this is the number of tablecloths and the price of the resin, which is not comparable in quality and price. Then, the know-how of a laminator knowing how to install and put in good conditions the materials in question.

What distinguishes Carbon for Tesla from Model Sport

A part that we have the chance to master, because we scrupulously analyze all the stages of production.

In the field of the production of carbon parts, the creator of the company Model Sport, François SPITALS, implements all his knowledge in the field of design and creation of automobile bodywork to provide the best in terms of finishing.

Fabric or carbon chips for Tesla?

The surprising mechanical properties of carbon are deliberately forgotten for its visual appearance in the world of aesthetic modification of our vehicles. In the Tesla realm, most carbon parts will not be subjected to any torsion or bending stress.

Automotive sportiness is the main purpose of these carbon components. Any type of carbon, even one that will be categorized as low-end, will be able to withstand the stresses imposed on it. To date, there are different categorizations of carbon stiffness.

But the most used being the "HR" or High Resistance for flexibility and versatility. The latter is the one used by the Model Sport company for the production of all its carbon elements. There is also HM carbon, which is literally referred to as “High Modulus”.

It is intended for elaborations that require extreme lightness, without any constraint involved. And if a constraint must be applied to it, it will be systematically combined with the HR. Forged carbon indicates this use primarily for its appearance than for its layout, however, it has many different characteristics.

The important role that resin gives to assembly

Now, let's show the centerpiece of carbon elements: resin.

Mass production of some carbon parts is usually produced with polyester resin. It is inexpensive and withstands high heat fairly well. In the field of motorcycles, polyester resin is used in combination with carbon to make exhaust cartridges.

Epoxy resin will greatly increase the endurance of parts subjected to residual loads. The various tests have confirmed that one resin stands out among many others: anti-UV epoxy resin.

It does not tarnish over time and maintains the true look of carbon. In addition to having a more transparent general appearance, the anti-UV Epoxy resin will not be affected by the effects of the sun. And this detail really makes all the difference, because without this treatment, you will have a carbon part that will yellow over time.

In order to know the price of the resin, we must consider three properties: the application, the quality as well as the ability to keep its appearance and its composition over time.

Let's talk about the selling price of this famous resin in France:
• 8 to 10€ for the kilogram of Polyester resin
• The kilo of Epoxy resin is worth between 50 and 60€
• The kilo of anti-UV Epoxy resin is worth between 55 to 65€

What is the finish coat on a carbon part?

The finishing varnish is the last essential touch in the production of carbon parts.

Initially, we produced carbon parts without using paint to guarantee long-lasting durability, however this singularity forced us to develop perfect parts the first time, with no possibility of catching up.

This construction process gives an unacceptable scrap rate given the image that the Tesla brand wants to convey: reducing pollution and carbon waste. We then found a solution to "standardize" the finishing work: the use of a superior quality varnish.

Once the glossy varnish has been applied, it will be carefully buffed to give it a polished surface. The mat, which does not benefit from any possible recovery thanks to polishing, is completed by a professional painter in one go.

Model S and X: their carbon evolution

There are many differences between the interiors of the Model S and X. However, it is true that many elements are practically identical.

It is for this argument that you will be asked for information about the year and month of production of your Tesla before shipment.

Tesla Model S or X, personalizing its interior

Tesla component tuning is much more popular on the Model 3, however your Model S and X can also receive interior upgrades.

Replacement carbon elements or even inserts that will simply cover the main trim elements.

The carbon steering wheel is also one of the modifiable parts that will give a different dimension to your life on board your Tesla. For the latter, we offer a very precise on-demand customization service that will give you total control when placing your order.

Model S and X exterior features

The electric sedan par excellence first receives the Performance spoiler. To guarantee an uncompromising result, the Model Sport version of the Performance spoiler will have a bonding surface as well as a unique internal structure.

Lighter, but also more adapted to the curvature of the trunk. Although the dissimilarities made on the parts indicated are not visible once the spoiler is in place, it will have the advantage of really having the lightness provided by carbon.

At this very moment, the latest version of the Plaid spoilers is also being designed for mass production as well. The grille or the mirror shells are also elements that will receive their carbon finish.

If you ever want a personalized creation based on Texalium or forged carbon, you can contact us by phone or email to find out more about your project on your Model S or X.

Carbon elaborations on Model 3 and Y

The Model 3 marked the advent of carbon in the Tesla world: it is the most modified electric vehicle today.

Let's take a look at the similarities with the Model Y, which shares many carbon accessories.

Model 3 and Y and their interior modifications

Carbon inserts have almost become a culture for the Tesla community. The feat of the inserts and succeeding in mass-producing an element that must scrupulously respect a given thickness in order to avoid the "addition" effect.

This is where the biggest challenge with inserts lies. It is for this reason that it took us numerous trials to finally succeed in manufacturing extremely fine inserts to cover a dashboard, a door trim, a central console or even an armrest while giving feels like part of the original finish.

An adjusted cut and gluing as close as possible to the components with a perfect finish, this is the recipe for a successful carbon insert for Model 3 or Y. For the most demanding owners, replacement carbon components are also highly appreciated by the Tesla community. The fine production of these carbon components will give you real carbon works of art in your vehicle.

Model 3 and Y: their body components

The Model Y or 3 bodywork is not to be outdone with a good number of possible carbon-based customizations. You can totally makeover your Tesla using 3K twill or forged carbon.

It concerns matte or glossy finish. One of the most popular components and undoubtedly the Performance spoiler in its matt version. For Model 3 or Y, it will always have a benefit compared to other carbon parts.

To be attached directly to the trunk (or trunk for the Model Y), it has become a standard for Tesla differentiation. You can also choose more advanced modifications like the real carbon front cover, an absolutely beautiful part that will really give you a weight loss, while keeping its use fully functional.