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2019 GMC Sierra carbon fiber bed: How it's made

FORT WAYNE, Ind. — The redesigned 2019 GMC Sierra has some pretty nifty features, and the one that has had the most attention is the MultiPro flipping and folding tailgate. But the Sierra also features the first-of-its-kind carbon fiber truck bed. It's interesting, of course, for its capabilities, such as being 62 pounds lighter than the all-steel box. It even adds more cargo volume since the material can be assembled and shaped differently from steel. As it turns out, the assembly process is cool, too, which we learned when GMC invited us to see the beds being made. Every GMC carbon fiber bed starts out as perfectly flat sheets of thermoplastic carbon fiber. The sheets consist of a mix of fibers and resins, a bit like the molded carbon fiber parts Lamborghini uses. The sheets are manufactured by Japanese company Teijin, which collaborated with GMC to develop the bed. They're all delivered to Continental Structural Plastics (CSP) in Fort Wayne, Ind., for construction into the actual bed. The company, a subsidiary of Teijin, makes a wide variety of composite and plastic parts for the car industry, including body panels for the C7 Chevy Corvette. The rectangular sheets are cut to shape and stacked up at a giant stamping press. Robots pick up sheets and slide them onto a conveyor that goes into a large oven. The heat softens the parts so they can be stamped. The large primary bed parts such as the base are stamped by CSP's enormous 3,600-ton press, and the smaller ones go through a 1,000-ton press. Each press can do different parts using different stamping dies, and CSP switches between dies to produce different batches of parts. After stamping, the parts roll out mostly ready for assembly, but there are rough edges that are trimmed off by water-jet cutters. These cutting machines also create holes for fasteners and for parts such as tie-down hooks and lights. The stamping process also provides the carbon fiber bed with a unique Easter egg. On the bottom of the base of the bed, there are two words: "Connors Way." This is a tribute to Tim Connors, who was the chief engineer of manufacturing at GM and a strong proponent of the carbon fiber bed. He was tragically killed in a motorcycle crash a few years ago. The words were added to honor him, and they were fortunately approved for production. There are some components to the bed that aren't stamped from the flat sheets of material.

GMC to get own model not shared with Chevy?

For years, GMC has existed as a brand without a single unique product, reconstituting Chevrolet trucks, SUVs and crossovers with more frosting in exchange for a few extra dollars. The Sierra is a Silverado, the Acadia a Traverse, and the Terrain an Equinox, although admittedly the latter pair are visually differentiated to a significant degree.
GMC could be set to expand beyond its Chevy-based roots, though. During last week's Detroit Auto Show press days, GM's product boss Mark Reuss was asked whether there'd ever be a GMC that wasn't taken from Chevy. "Oh, yes, you will," Reuss told the media. "The health of GMC is astonishingly good from a consideration standpoint." Reuss wouldn't elaborate on what the model could be, although we're quite happy to make some guesses. GMC has its bases fairly well covered, with a mid-size and full-size crossover, as well as a mid-size, full-size and HD pickup. We doubt GMC will be building a family sedan, sports car, or hatchback, so really, the only place we can see the brand going is into a smaller crossover.
Automotive News points out that the most recent small GMC showcar, the 2010 Granite concept (shown above), won't see production according to General Motors. That vehicle likely would have rode on GM's compact vehicle architecture, known internally as Gamma II, which underpins the Chevy Spark and Sonic, as well as the Buick Encore (and its overseas Opel/Vauxhall/Chevy counterparts).

GMC Hummer EV could have had the Chevrolet Avalanche's Midgate

One of the many rumors swirling around the GMC Hummer EV claimed the truck would resurrect the Midgate inaugurated by the original Chevrolet Avalanche. Although we now know there's no way to fully knock down the partition between the cab and the cargo box, the firm revealed the rumor wasn't entirely false. "There was [a Midgate] early on. We opted for the functionality of the drop glass in the back. With the package layout and things like that, it was not advantageous to pursue that one. And, the five-foot bed was kind of the industry standard in regards to price of entry in that segment," explained John Mack, the Hummer's exterior design management, during an interview with Muscle Car & Trucks. The Hummer will go on sale with a five-foot box, and it doesn't sound like a longer bed will be available, so a modern version of the Midgate would have made the model more versatile by giving users the ability to fold down the partition behind the rear seats to carry bulky items, like plywood and ATVs. It's a feature that would have inevitably made the truck more complicated to build, however, because it adds moving parts that need to be sealed. Hinges, seals, and latches in turn add weight, and complexity almost always invites high manufacturing costs. As an electric pickup built with newly-developed components, the Hummer already has enough of each. Motorists who need to carry something that's significantly longer than the cargo box aren't entirely out of luck. As Mack pointed out, the rear window drops into the partition, so owners will have the ability to haul surfboards, lumber, or anything else that's relatively long and reasonably thin by simply pushing a switch. Alternatively, the only thing limiting cargo space when the roof comes off is the sky — or, depending on where you live, bridges. Mack didn't reveal when the Midgate was dropped. GMC launched the Hummer project in April 2019, and it previously released early design sketches that show how the truck transitioned from a sketch to a prototype. As of writing, nothing suggests the Midgate will make a comeback in the near future on any member of the General Motors portfolio. It was introduced in 2001 on the first-generation Chevrolet Avalanche, which went on sale in the United States for the 2002 model year. It later spread to Cadillac's luxed-up variant of the truck, the Escalade EXT, and to the short-lived GMC Envoy XUV.