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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.

GM updating fullsize pickups for 2015

As Ford prepares to hit the market with its x-factor, aluminum-intensive F-150 and Ram sales stand tall enough to meet General Motors truck sales eye-to-eye, GM is putting the word out that it's going to add more features to its trucks and do so more regularly. An executive engineer for pickups told reporters that "a whole array" of changes are on the way as soon as the 2015 model year and then would likely come "the year after that, the year after that, the year after that."
Only GM knows the way it plans to go with its fullsize trucks, with almost everyone else - including its dealers - griping about market share at the same time as they applaud profits and hope for clarity and growth. GM raised prices on the Chevrolet Silverado and GMC Sierra not long after launch even as it was losing market share and getting called "the least successful large pickup launch over the last 15 years," further upsetting dealers, then Ram outsold the Silverado in March of this year and led GM to increase incentives. But transaction prices rose with the premium; in the first quarter of this year more than 37 percent of the trucks costing more than $40,000 were the Silverado and Sierra, leading one dealer to say of the Sierra, "You can't sell a cheap one," and the analyst who made that "least successful launch" comment to opine, "GM may have made the right call to go for price over share."
We won't know for a few months what any of these updates will be, but the rumored changes for the Silverado and Sierra appear to cover all the bases, including appearance, capability and fuel economy. Rumors run to higher gear counts, stop-start technology and diesel engines before brand-new pickups come for the 2019 model year, those next-generation models supposedly to be engineered with a lot more aluminum.

GMC Sierra Denali CarbonPro bed is finally, almost here

GMC revealed the Sierra 1500 with the optional CarbonPro bed on March 1, 2018. The bed wasn't available at launch, though. You can't buy it now, either, but it will hit dealerships with limited availability after production starts in early June, exclusively for the Denali 1500 and AT4 1500 trims. The carbon floor and sides replace the steel panels in a normal bed, providing "strength, durability, and scratch resistance" and a potential 59-pound weight saving, depending on the truck's configuration. To make sure the bed had a chance, development engineers replicated "extreme use scenarios" like dropping 1,800-pound gravel loads, 450-pound steel drums, and cinder blocks from various heights. They put a 250-pound man on a snowmobile with studded tracks, had him drive into the bed and then go wide-open throttle. We're told the result was "minimal scratching." On top of the extreme weather testing any vehicle goes through, the team also put a generator in the bed and aim the exhaust into a corner to ensure vibration and direct heat wouldn't deform the carbon fiber. Because of the finer shaping area-specific strength possible with carbon fiber, the bed provides one cubic foot of additional payload space by having its sidewalls pushed further out. The CarbonPro bed doesn't need a bedliner, and is grained at the top for better traction but smooth on the bottom for easier hosing down and dirt removal. Tie-downs at the front of the bed work with molded indentations to hold motorcycle tires, and slots in the sidewalls hold two-by-sixes. The truck maker says the carbon-lined payload area confers "best-in-class dent, scratch and corrosion resistance," but we suppose the nation's pickup truck army will prove that or not. The trucks likely won't have the hardest life at the start, since the Sierra Denali costs $56,790 before even a basic option like four-wheel drive. The real test probably won't come until around 2029, when third owners begin treating their aerospace-inspired thoroughbreds like dray horses.