Carbon Grille
Tesla Model S

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The outstanding benefit of Model Sport regarding the manufacture of carbon? What is a composite material? The true definition of a carbon element?

We are going to focus our development around three paragraphs:
• It is interesting to look once and for all at what carbon really is
• The unique qualities of carbon from Model Sport
• Anything you can customize

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

What is a composite material

A composite material is an alliance of two elements which cannot unite with each other in a homogeneous way, but together they give a material with superior mechanical properties.

What kind of carbon or Texalium for your Tesla?

There are different types of carbon and above all different ways of presenting it and placing it in its final location.

What ordinary mortals call "carbon" is actually determined by "a composite of carbon fiber", it is important to know in the world of lamination this is the designation that is used.

200 gram 3K twill carbon membrane:

Let's start our development with the most popular of all: 3K carbon twill. In reality, the term "twill" is an attribution that serves to qualify the mesh of the carbon fabric.

The figure above is just there to give you an example of this. There is an argument for twill to be very noticed: firstly its ability to adapt to molds with a strong curve, secondly its aesthetic appearance giving the impression of a diagonal weave. That said, we will not detail the type of interlacing in 3/1, 2/2 and 4/4.

The abbreviation "3K" means that 3000 carbon filaments are part of a single frame. As a rough guide, a strand of carbon is only 1/20th the thickness of a hair.

Actually, there are several varieties; the best known of which are 1K, 3K, 6K and 12K. The Tesla community is particularly accustomed to observing 3K.

As for the weight stated when selling a carbon sheet, if it is mentioned "200gr/m²", this announces the weight that 1m² of this sheet weighs before it is confused with a resin. 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 aspect.

The unknown in its class: forged carbon

This name forged is reminiscent of other denominations, but you should know that forged carbon is not innovative and that it owes its name to a unique molding method.

To develop it, you must first cut the carbon into small strips and arrange it more or less evenly in 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. The method used for the production of forged carbon thus gives a big advantage on rigidity and lightness, because the density of carbon obtained per square centimeter compared to the resin is higher.

You have to go back to the 80s to discover the first uses of forged carbon in the warhead manufacturing industry, however this development process was noticed only from its use at the Lamborghini brand .

Texalium, the unknown:

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 characterize what Texalium is: we can assimilate it to glass fabric which is loaded with aluminum and then tinted, either in the mass with resin, or with the finishing varnish with a color a choice.

You should know, however, that its mechanical properties are less than those of a usual glass fabric. And its application is purely aesthetic. Much better known in the United States, he barely manages to make himself known in France.

Visually, how do you appreciate the appearance of real carbon?

We are going to provide you with some insights into using carbon fiber.

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

Is carbon resistant?

It is legitimate to wonder if the resistance of the material is up to the task, but compared to what? It is the relationship with other materials that must first be established.

To give you an idea, even at equal volumes, a carbon part is relatively more durable than an aluminum alloy part. However, this term "resistant" sums up a fact that should not be generalized. Even if carbon is less durable to impacts, it has surprising qualities when twisting or bending.

This is one of the aspects of carbon that allows us to develop components as thin as inserts. The Model 3 or Y dashboard insert is a good look at this. 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 shipped throughout France without suspicion of breakage.

Carbon fabric and its purchase price?

Let's go back to the production of the carbon cloth to assimilate the price of it. The technique of shaping a carbon weft is already complicated enough. The most used is from a synthetic fiber, polyacrylonitrile, which will be oxidized and calcined to give us the famous carbon fiber.

It is an entirely chemical and very energy-intensive transformation. As you can imagine, the production of carbon fiber involves a number of chemicals that are certainly not good for the environment.

It is for this reason that many institutions are creating projects to continue the production of carbon fiber in the future, while drastically reducing the application of non-natural products. There is an exponential growth in demand for the use of bio-based materials to remove the vast majority of chemicals and also cut the price in half.

The carbon production operation also requires expensive and bulky specialized equipment, not to mention its weaving. The carbon strand remains an absolutely fantastic creation, if we keep in mind that it is only 1/20th the thickness of a human hair.

To give you a price, which remains indicative, because it is subject to variations in the world economic price: €30 per square meter.

This price is given for a 3K twill carbon tablecloth that weighs 200gr per square meter. Do not forget that we must add to this the cost of the resin, which we will see can have totally variable prices depending on its quality, and also that very often, if not all the time, a carbon part is produced in many layers.

Finally, an experienced laminator must be used to install the product. Moreover, the operation must be carried out under specific conditions.

The carbon of Model Sport and its unique layouts

Let's move on to the part that we master, because we follow all the manufacturing steps. One of the foundations that will assure you of successful results in any area is “who are you listening to?” Listen only to people who have the results you want to have”.

You must therefore turn to the creator of the company Model Sport, designer and body builder, to find the expertise necessary for the development of carbon components for your Tesla.

A carbon weave or a laminated version?

It is an indisputable fact, in the 21st century carbon is mainly used for its finish, more than for its primary use: its mechanical skills and its lightness. In the Tesla domain, all of the carbon parts will not be subjected to any torsion or bending stress.

Components are specifically manufactured to enhance aesthetics and highlight the aggressiveness of the brand. The constraints will be largely cashed on the Model S, 3, X or Y equipped with a body kit, even if it uses low-end carbon (be aware that it is difficult to develop so-called "poor" carbon). quality ").

However, there are several varieties that will determine the stiffness of carbon, the most common being HR (high resistance) because it is the most flexible and versatile. 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. The parallel we can draw is forged carbon, which has superior mechanical function, but is used for its different aesthetics.

Does the resin used play a role in the quality of the finished part?

Now let's talk about the key element of carbon parts: the resin.

Mass production of some carbon components is usually produced with polyester resin. It is inexpensive and withstands high heat fairly well. In the motorcycle industry, polyester resin is used in combination with carbon to produce exhaust cartridges.

The primary benefit of epoxy resin is the resistance to stress it provides compared to polyester. It is a good omen to specify that on this point, we make the difference: the application of an anti-UV epoxy resin is obvious for Model Sport, this one avoids yellowing of the parts over time.

Apart from its more translucent appearance, the anti-UV Epoxy resin will resist solar attacks. It will be perfect during installation, but beware of periods of heat wave, otherwise you will notice a yellowish and opaque appearance in a few years.

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

At this stage, it is interesting to observe the selling price of such a product in France:
• 1kg of Polyester resin = 8 to 10€
• 50 to 60€ for the kilogram of Epoxy resin
• €55 to €65 for the kilogram of anti-UV Epoxy resin

Paint finish for Tesla

It must be said that this is the operation that closes the project. To guarantee an almost infinite hold over time, at the very beginning we manufactured carbon components without any finishing paint.

The problem was that production was needed with no possibility of catching up and therefore a high rate of “waste”. The ambition of the Tesla brand being to reduce pollution and waste, it was a counterproductive idea to get so much waste.

To obtain a more "standard" result in the manufacture of our carbon elements, we have therefore started to use a higher quality varnish. The application of the matte varnish is carried out with care, as well as the polishing of the parts with a glossy finish to guarantee a perfect appearance.

Model S and X: their carbon evolution

Although many elements are corresponding in the two versions, there are some differences between the years.

It is with this in mind that it is mandatory for us to call you, after ordering, to find out the year and month of production of your vehicle.

Tesla S or X interior trim

Although less widespread than our valiant Model 3, the Model S and X also have the right to some modifications and real carbon components. The dashboard, the cup holder area or even the central console can receive a trim that differentiates it from the original.

The predominant point, the steering wheel, can also benefit from customization with leather or Alcantara trim, depending on your choice.

For the latter, we offer a very precise personalization service on demand which will give you total control when placing your order.

Model S and X exterior features

The performance spoiler for the Model S is the most sought after for the latter. Always keen to make a difference, the matt Performance spoiler will benefit the Model Sport version from a rectified bonding surface and a lighter internal structure.

This change is subtle, so much so that it won't be visible once the spoiler is installed, however these details make all the difference. We are also currently working on the Plaid version as of this writing.

The grille or the mirror caps are also parts that will receive their carbon finish. Although 3K twill carbon is the most common, more "exotic" creations such as Texalium may be the subject of a study, in this case contact us by phone or email.

Model 3 and Y: perfect bases for carbon fabrication

The advent of carbon in the Tesla world has actually appeared since the launch of the Model 3.

Share a lot of similarities with the Model Y, let's see what you can find more about them.

The Model 3 and Y and their cabin upgrades

The Tesla community gets a certain culture of its own, carbon inserts are part of it. A successful carbon insert must partly be finely cut so as not to manufacture an "add-on" effect. It is for this argument that it is so difficult to develop it in series. This is where the biggest challenge with inserts lies.

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

Replacement elements such as the carbon dashboard combined with the door trim will give your vehicle a real finish in the chosen material. The carbon dashboard and door trim are works of art that will add another dimension to the interior of your Tesla.

Model 3 and Y: exterior modifications

As with the interior, the exterior of the Model 3 and Y have a large number of possible modifications. You can totally makeover your Tesla using 3K twill or forged carbon.

It concerns matte or glossy finish. Regarding the Model 3 and Y, the performance spoiler in its matte version is relatively busy. To be fixed directly on the trunk (or trunk for the Model Y), it has become a standard for Tesla personalization.

To combine the two advantages of carbon, which are weight loss and a sportier appearance, you can opt for a more substantial upgrade such as the carbon front cover.