Carbon seat backrest
Tesla Model S

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Want to know what makes Model Sport carbon special? What is a composite material? A carbon part: what is its interpretation?

Three points are essential to explain the product:
• It is interesting to look once and for all at what carbon really is
• The unique properties of the carbon used at Model Sport • What you can find

When you finish this page, no detail will escape you.

What is a composite material

By designation, what is called composite material evokes the assembly of two elements together, which do not mix, but which produce 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.

What to choose between the many types of carbon or Texalium for electric sound?

What we can mention is that many carbon or Texalium parts exist and that many ways of presenting it in your vehicle are possible.

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

200 gram 3K twill carbon fabric:

3K carbon in twill weave is undoubtedly the most common of its variety, let's start with this one. Each way of weaving carbon has a specific name, that of twill is one of them.

Look at the twill weave in the image just above. There are still different methods for weaving carbon, twill is highly valued for its ability to adjust to the shapes of molds with pronounced curves.

However, we will not clarify the type of 3/1, 2/2 and 4/4 interlacing for the sake of understanding. The sign annotated "3K" has for definition the total number of filaments which shapes a single carbon frame, in total unit: 3000 filaments. As a rough guide, a carbon filament is only 1/20th the thickness of a human hair. To use the most common names and varieties on the market, there is 1K, 3K, 6K or 12K.

For Tesla vehicles, we particularly appreciate 3K. 200gr/m² means that the carbon fabric, before its combination with the resin, weighs 200 grams for a tablecloth of 1 meter x 1 meter. For the Tesla community, the 3K twill in 200gr/m² is the most appreciated for its aesthetic configuration considered much better than its comrades, but in no way for its mechanical resistance properties.

Let's talk about forged carbon:

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

To give you a simplistic definition, so-called "forged carbon" refers to a unique production process: carbon fiber is cut into small pieces and then dispersed evenly in a mold.

Then, the positive and negative molds are put under specific temperature and compression conditions once the resin is added. This molding technique is the most elaborate 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 ratio in favor carbon.

Lamborghini is the pioneer in the application of forged carbon in the automotive field. However, it should be known that forged carbon has been used in the production of warheads since the 1980s.

A material worth explaining: Texalium

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

Really, Texalium is a kind of glass fabric loaded with aluminum to give it a natural highlight. It can thus be nuanced either in the mass, by mixing a dye with the resin, or on in the varnish.

Essentially decorative use for this finish, because its mechanical provisions are less compared to simple glass fabric (which itself is below carbon). Know that Texalium is a material that has existed for years, but is little used in France. It is also much more widespread and on the Atlantic side.

How to physically recognize carbon?

We are going to provide you with some examples of how carbon fiber can be used.

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

Is carbon resistant?

Frequently asked, this is a request that deserves a little more in-depth development. It is the relationship with other materials that must first be established.

As a guide, 1 kg of carbon is stronger than 1 kg of aluminum alloy. However, this term "resistant" sums up a fact that should not be generalized. Indeed, a carbon part is very resistant to bending and torsion.

But less solid on impact. It is for this reason that we find such fine parts for the Tesla brand. For model 3 or Y, the dashboard cover insert is a very good example. Only two layers of carbon fabric are used to develop a 1m40 long piece, which will be shipped throughout France without any inconvenience of breakage.

The reason for the cost of buying the carbon cloth?

Let's go back to the production of the carbon fabric to assimilate the price of it. The precedent of making a single carbon fiber is already quite complex.

It takes a very heavy production process in terms of energy consumption to develop carbon fiber: we start with a specific synthetic fiber, called polyacrylonitrile, which will have to be put under oxidation and then carbonized with a specific way to obtain carbon fiber.

The awareness of more and more industries of carbon fiber production gives rise to certain projects, entirely directed with the aim of manufacturing it using the least possible chemical products. The application of bio-sourced materials is gradually emerging to eliminate chemicals on the one hand and halve the price on the other.

The tools needed to produce the raw material of carbon are substantial, as are the tools for weaving it. Keep in mind that compared to a human hair, a carbon fiber is 20 times thinner.

30 euros per square meter is the average price, at the time of writing, that you can find a 200gr/m² 3K twill carbon sheet.

Don't forget that we must add to this the cost of the resin, which we will see can have essentially variable prices depending on its quality, and also that very often, if not all the time, a piece in Carbon is produced in a multitude of layers. Finally, the intervention of a qualified laminator is essential. This in order to carry out the operations in good conditions.

What differentiates carbon for Tesla from Model Sport

We will follow and prioritize all the production steps of our carbon components, so let's get to the most essential part.

One of the principles that will guarantee you positive results in any area is "who do you listen 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 know-how necessary for the development of carbon components for your Tesla.

A Tesla dressed in carbon weave or its 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 capacities and its lightness. In the Tesla realm, most carbon parts will not be subjected to any torsion or bending stress. The components are expressly manufactured in order to improve the aesthetics and highlight the aggressiveness of the brand.

For the entire Tesla range, the constraints generated on the components, even a body kit, will be largely absorbed, even on a so-called "low-end" carbon. It is necessary to combine flexibility and versatility to find the most used type of carbon: HR, for "high resistance", is the reference in the field.

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. Likewise for forged carbon, it will be used to prioritize the final appearance.

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

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

For any piece that is intended for the general public and that requires mass production, polyester will be prioritized with the use of fiberglass. You should know that for carbon parts that will be very exposed to heat, polyester will also be used for its high resistance to high temperatures. It is this resin that is used for the production of exhaust cartridges for motorcycles, for example.

The primary benefit of epoxy resin is the resistance to stress it provides compared to polyester.

We intentionally use, after numerous tests, Epoxy resin, and not just any resin: it has an anti-UV treatment that will prevent it from tarnishing or yellowing over time. Apart from its more translucent configuration, the anti-UV Epoxy resin will resist solar attacks. And this detail really makes all the nuance, because without this treatment, you will have a carbon part that will yellow over time.

You won't notice anything abnormal during the purchase for sure, it is after a multitude of summers that you will begin to discern an opaque and tarnished appearance of your carbon.

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

For the French market, the selling prices of the resin are given below:
• 8 to 10€ for the kilogram of Polyester resin
• The kilo of Epoxy resin is worth between 50 and 60 €
• €55 to €65 for the kilogram of anti-UV Epoxy resin

Paint finish for Tesla

Varnish is the end point of a carbon part.
We are so meticulous that the initial project was to mass-produce carbon parts that did not require a finishing varnish. So once out of the mould, they had to be perfect.

Which leads to a very high and counterproductive scrap rate taking into account that the spirit of the Tesla brand is to reduce pollution, so this mess was nonsense. Applying a premium topcoat seemed like a no-brainer.

It is for this argument that high quality varnish has become essential in our production logic to "standardize" the process. The application of the matte varnish is carried out meticulously, as well as the polishing of the parts with a glossy finish to guarantee a perfect appearance.

Carbon weaving on the Tesla Model S and X

At first glance, both vehicles have all of their interior components similar. However, a certain number of parts remain very individual depending on the year of registration.

Don't be surprised to receive a call after ordering to find out the year and month of registration of your vehicle.

Model S and X interior

Although less widespread than our valiant Model 3, the Model S and X also have the right to some improvements and elements in real carbon.

Inserts such as for the dashboard, the central console or the part of the cup holder. The predominant point, the steering wheel, can also benefit from a fine-tuning with leather or Alcantara trim, depending on your choice.

You thus have total control, during your order, on all characteristics of the latter.

Model S and X bodywork

The most sought-after body element on the Model S is undoubtedly the Performance Spoiler. As with all Model Sport spoilers, the internal structure as well as the entire bonding surface are ground in advance.

Once the spoiler is in place, no difference is visible. The Plaid version is also in production at the time of writing this paragraph. The carbon finish is so versatile and in demand as components such as the mirrors or even the grille.

If you ever want a custom 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.

On the Tesla Model 3 or Y, what type of carbon construction?

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

Tesla's two best-selling nuclear cars share many similarities.

Model 3 and Y interior

Part of the Tesla family of owners became aware of the carbon inserts for Model 3 or Y. Producing such a thin element in large quantities while maintaining a similar quality is a technical feat. Each insert must be able to be installed without giving an "addition" effect.

This is where the biggest challenge with inserts lies. The door, dashboard and other central console trim required a number of different tests to find the right technique and the right mold to make these inserts of incomparable quality.

Precise cutting and gluing as close as possible to the elements with a perfect finish, this is the recipe for a successful carbon insert for Model 3 or Y. But you can just as well opt for a real carbon replacement element, which will be positioned directly in place of the changed part.

For purists who love beautiful parts with meticulous manual work, the carbon dashboard and door trim will satisfy you.

The body parts of a Model Y or 3

Again, for the Model 3 and Y, the body modifications with carbon components are really good.

A good way to transform the external visual configuration, with a composition in 3K twill or forged, and matte or glossy finish. The Performance spoiler is a must in the series of carbon parts for Model 3. The same goes for the Model Y.

This will take up its final position on the edge of the trunk and will extend the lines of your Tesla. A more radical development could be the swapping of the front cover with a carbon version. Two advantages: weight loss and timeless style.