Carbon door sill
Tesla Model 3

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Do you want to know the basics and results of the Model Sport carbon production process? Composite material: its characterization?

A carbon part: what is its explanation? Let us present these ideas around three main axes:
• the true meaning of what is called a carbon element
• The contrasting vision of the Model Sport brand in the production of its carbon parts
• All customizations for your reference electric You will be able to offer yourself a carbon component with complete confidence.

Definition of a composite material

This type of production is a good way to obtain an object with high mechanical properties while using two components that cannot mix with each other, but which can be combined.

What are the types of carbon or Texalium for your Tesla?

Carbon certainly has many variations and above all there are many ways to implement it.

The term "carbon" is not complete; since it is in truth "carbon fiber composite". This designation is more accurate.

3K twill carbon fabric in 200gr:

Let's start with the most common of carbon fiber composites, 3K carbon in twill mesh. In other words, what is called "twill" is a name given to a certain way of weaving carbon.

The figure above is just there to give you an example of this. There are many ways to weave carbon, twill is very popular for its ability to match the shapes of molds with pronounced curves. To condense as much as possible, we will not detail the type of interlacing in 3/1, 2/2 and 4/4.

A major thing to assimilate with regard to the designation "3K", this characterizes the number of strands that make up a single frame, in this case: 3000. 1/20th the thickness of a hair: this is an order of magnitude that will let you know the diameter of a single strand of carbon. To designate and name the most common types of carbon used in the various fields of industry, we must mention 1K, 3K, 6K and 12K. The 3K is the most popular in the Tesla world.

As for the weight stated when selling a carbon sheet, if it is indicated "200gr/m²", this characterizes the weight that 1m² of this sheet weighs before it is confused with a resin. For the Tesla community, the 3K twill in 200gr/m² is the most noticed for its aesthetic aspect considered much better than its comrades, but not for its mechanical endurance provisions.

The unknown in its class: forged carbon

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

The "forged carbon" technique is actually very simple and ingenious: the carbon fiber is cut into small pieces and then placed in the mould. Once the resin has been added, the mold is pressurized (with a positive and negative master) then heated to high temperature.

This molding method is the most sophisticated to obtain a stiffer and lighter part than any other type of carbon: all the excess resin is evacuated during the pressurization, so you can accentuate the carbon / resin in favor of carbon. Lamborghini is the pioneer in the use of forged carbon in the automotive field. However, it should be noted that forged carbon has been used in the development of warheads since the 1980s.

Texalium, the unusual:

It is essential to make room for this material so taken for carbon. However, it is necessary to make the distinction of Texalium.

To roughly define what Texalium is: we can assimilate it to glass fabric which is loaded with aluminum and then dyed, either in the mass with resin, or with the finishing varnish with a color of your choice .

An entirely decorative application for this finish, as its mechanical properties are less than simple glass fabric (which itself is below carbon). Note that Texalium has been around for many years and is just beginning to take its place in certain tune-ups in France, but it is much more widespread and used in the United States.

Carbon: what is it?

We are going to present you various pieces made from this famous fiber.

Note that if you are interested in one of these versions, Model Sport remains open to customization and can therefore provide you with a quote.

Can carbon be subjected to high loads?

An oft-mentioned question, perhaps in the wrong way, but rightly so. It is very eminent to ask whether the famous carbon is more resistant than another material?

At equal volume, a carbon part will be more durable and much lighter than an aluminum alloy, for example. "Resistant" is a term that can have several meanings. Even if carbon is less durable to impacts, it has surprising qualities when twisting or bending. It is for this reason that for Tesla cars it is so common to make ultra-thin carbon inserts which are fixed on existing parts without risk of breakage.

Take the example of the dashboard cover insert, which is ultra-thin. However, it should be noted that this object of more than 1.40 m can be produced using only 2 layers of carbon. It can then be transported throughout the French country or other neighboring countries.

The reason for the cost of purchasing the carbon cloth?

One of the key parameters to explain the price of carbon fabric is to look at its production. The technique of shaping a carbon frame is already relatively complicated.

The method that prevost compared to the others is composed in this way: a specific synthetic fiber, a polyacrylonitrile, will be oxidized and then carbonized to finally deliver what is called carbon fiber.

It takes a lot of energy to achieve such a chemical mutation. In this day and age where more and more environmentally conscious industries are waging war on chemicals, it should be noted that more and more organizations are looking for solutions to continue manufacturing carbon fiber, respected for its lightness, while having an eco-responsible production method.

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

Remember that a fiber is 1/20 the thickness of a human hair. In terms of price, to give you an order of magnitude, the square meter of 3K twill carbon fabric in 200gr/m² costs around €30. It is also necessary to consider the price of the resin used and the number of layers to be applied. Finally, the fees of an experienced laminator are to be considered.

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. It takes knowledge of the actual layout of an element to be able to guarantee an acceptable result.

It is for this reason that the creator of the Model Sport brand, designer and bodybuilder, makes every effort to deliver its know-how in the field of carbon components.

A Tesla dressed in carbon fabric or its laminated version?

The carbon fabric used is intentionally focused on its aesthetic appearance before its mechanical properties. No constraints, most of the time, will be subject to the elements installed on your Tesla. Automotive sportiness is the main purpose of these carbon elements.

Any type of carbon, even one that will be categorized as low-end, will be able to withstand the constraints imposed on it. To date, there are several categorizations of carbon stiffness. But the most used being the "HR" or High Resistance for flexibility and versatility. For all the carbon parts of your Tesla, Model Sport is also based on this type of carbon which is very widespread and so practical on several points.

We can compare it to the HM (High Modulus) which will be much lighter. But on the other hand, it is also much more brittle, so brittle that it must be combined with HR to guarantee its function. Forged carbon indicates this use primarily for appearance than for its properties, however, it has many different characteristics.

Which resin for carbon fiber?

Here we enter the most interesting area of ​​this description: resin.

The mass production of certain carbon components is generally produced with polyester resin. It is inexpensive and withstands high heat fairly well. You will find it in the manufacturing operation of motorcycle exhaust cartridges.

Elements subjected to loads or forces are primarily used with Epoxy, because it provides greater resistance to the composite material. We intentionally use, after numerous tests, Epoxy resin, and not just any resin: it has an anti-UV treatment that will allow it not to tarnish or yellow over time.

The sun's rays will therefore have little or no effect on your cabin or body components and the overall appearance will be more translucent. The appearance can be perfect when setting up the piece, but be careful as soon as summer arrives in force, it will gradually tarnish and become opaque. The resistance over time is a determining point for knowing the price of a resin, as well as its quality of realization and its field of application.

Although the price may vary depending on the manufacturers and retailers, it is interesting to make a comparison on French territory between these multiple resins:
• The kilo of Polyester resin is worth between 8 and 10€ • The kilo of epoxy resin is worth between 50 and 60€
• The kilo of anti-UV epoxy resin is worth between 55 and 65€

The final varnish applied to the carbon parts

It must be said that it is the operation that closes the project. In the past, no paint was applied to the carbon components at all. The reason is that this ensured the longevity of the elements.

On the other hand, you had to get it right the first time. The ambition of the Tesla brand being to reduce pollution and waste, it was a counterproductive idea to get so much waste. Using a premium topcoat seemed like a no-brainer.

It is for this argument that the high quality varnish has imposed itself in our production process to "standardize" the process. The glossy varnish is finely polished before shipping and the matt varnish applied delicately to have a uniform appearance over the entire piece.

What kind of carbon fabric do we find on the Tesla Model S and X

Although many elements are corresponding in the two versions, there are some differences depending on the year.

So in most cases we call the owner, after ordering, to find out more information about the vehicle.

Model S and X interior

The Model S and X have been forgotten by props since the launch of the Model 3, however these also benefit from a range of modifications provided. Inserts such as for the dashboard, the central console or the part of the cup holder.

One of the main elements of your Model S or X is undoubtedly the steering wheel. This can be personalized to infinity, in twill or forged carbon, glossy or matte and leather or Alcantara trim. You thus have total control, during your order, on any characteristic of the latter.

Model S and X: body parts

The electric sedan par excellence receives the Performance spoiler. To guarantee an uncompromising result, the Model Sport version of the Performance spoiler will have a different bonding surface and internal structure. Lighter, but also more adapted to the curvature of the trunk.

This difference will not be seen once the Spoiler is installed. We are also currently studying on the Plaid version at the time of this writing. Carbon adapts to all supports. Although it is very often used in the particular field of the automobile only for its appearance, it will find its place on elements such as the grille or the hulls of mirrors, with a slight loss of weight in passing.

Although 3K twill carbon is the most common, more "exotic" elaborations such as Texalium may be the subject of a study, in this case contact us by phone or email.

Carbon elaborations on Model 3 and Y

The most modified electric vehicle of all time is undoubtedly the Tesla Model 3, which receives an incredible number of carbon-based modifications.

Many of the parts are similar to the Model Y (except the Berlin one), it's interesting to look at what you can find in these two electrified icons.

Model 3 and Y and their interior improvements

Part of the Tesla community is undoubtedly familiar with carbon inserts for Model 3 or Y. The feat of the inserts and of succeeding in mass production of an element that must scrupulously respect a given thickness in order to avoid the "addition" effect. It is on this assumption that the quality of an insert must be judged.

The door, dashboard and other center console trim required a number of different trials to find the right method and the right mold to make these inserts of incomparable quality.

The keys to a quality insert are tight cutting and precision gluing. Carbon replacement parts, however, are making more and more careful owners happy. For purists who love beautiful parts with meticulous manual work, the carbon dashboard and door trim will satisfy you.

Model 3 and Y: their body parts

As with the interior, the exterior of the Model 3 and Y has a number of possible upgrades. In a gloss or matte finish, with 3K twill or forged carbon, you can transform your entire Tesla.

The Performance spoiler is a must in the series of carbon parts for Model 3. The same goes for the Model Y. An element that has become a standard over time, the spoiler will stick to the edge of the trunk to give your Tesla its sporty side.

In addition, you can order more essential upgrades such as the replacement of the genuine carbon bonnet. Not only will this allow for weight loss, but will give the car a standout style.