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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 doubles miles open to its Super Cruise technology

DETROIT — General Motors said on Wednesday owners of certain vehicles equipped with its Super Cruise assisted driving system will now be able to use it on 400,000 miles (643,740 km) of North American roads, doubling the current operating area as Tesla and other automakers race to deploy hands-free cruising technology. GM's Super Cruise system, like Tesla's Autopilot system, is a driver assistance system, and does not enable true autonomous driving. Spurred by Tesla's aggressive deployment of Autopilot, and Tesla Chief Executive Elon Musk's promises of a more advanced "Full Self Driving" system, GM, Ford, Volkswagen and Mercedes-Benz are racing to deploy competing partial automation technology in major markets. At the same time, safety regulators are showing concern that drivers do not understand that Autopilot and similar systems are not designed to take over driving in every circumstance. The GM system's sensors and software allow a motorist to cruise with hands off the wheel on highways that have been mapped in detail. But the driver is expected to stay alert and ready to take over the car. GM uses technology to monitor the driver, and Super Cruise will sound alarms or slow the car to a stop if it detects that a driver is not responding. Starting later this year, GM plans to enable vehicles equipped with Super Cruise and the company's latest vehicle electronic system to operate hands-free on major, undivided highways in the United States and Canada, as well as additional miles of divided, interstate highways. Currently, Super Cruise operates only on interstate, divided highways. The expansion, enabled by wider digital mapping, will allow owners of properly equipped GM vehicles to cruise hands-free on stretches of Route 66 and the Pacific Coast Highway in the U.S. West or the Trans-Canada highway in Western Canada, GM said. Many of the new roads GM has mapped are in rural, heartland states where GM pickup trucks are popular. GM plans to offer Super Cruise as an option on its Chevrolet Silverado and GMC Sierra large pickups later this year. GM has said previously it intends to offer Super Cruise as an option on 22 models by the end of 2023. Depending on the model, Super Cruise costs $2,200 to $2,500 to add as an option. (Reporting by Joe White in Detroit; Editing by Matthew Lewis) Related video: Cadillac Chevrolet GM GMC Technology Super Cruise

GM readying aluminum-body fullsize pickups

Ford's extensive use of aluminum in its 2015 F-150 is a big deal. A really big deal. Big enough, in fact, that General Motors is reportedly changing its fullsize pickup strategy. According to The Wall Street Journal, The General has locked in partnerships with Alcoa Inc. and Novelis Inc. - companies that will supply aluminum for the next-generation Chevrolet Silverado and GMC Sierra trucks.
"Ford's introduction of the 2015 F-150 pickup truck was a game changer, and it's the first, not the last, conversion of this type," Novelis spokesperson Charles Belbin told the Journal. The switch to aluminum has allowed Ford to shave roughly 700 pounds off its fullsize truck's curb weight. And while official mileage ratings have not been announced, the weight loss should go a long way for improving efficiency, especially when combined other efficiency-minded improvements including better aerodynamics and new, turbocharged V6 engines.
Of course, aluminum-bodied cars are nothing new. But extensive use of aluminum in a major, best-selling product like the Ford F-150 is expected to kick off widespread use of this weight-saving material as availability rises and cost decreases. The WSJ reports that GM had originally explored the idea of moving to aluminum pickups back in 2008, but abandoned the idea due to cost concerns amid economic woes.