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In the fast-paced world of automotive design innovation, sometimes the most groundbreaking solutions are decades old. In this teardown and analysis, we deliver a compelling argument for the future of electric vehicle (EV) design—by looking to the past. From carbon fiber frames to molded-in-color plastics, these so-called “old” innovations are quietly reshaping the automotive design landscape.
Let’s explore how yesterday’s breakthroughs are defining tomorrow’s vehicles.
Molded Plastics: Eliminating Paint Shops and Saving Millions
The Club Car Precedent, launched in 2004, stands out as an example worth highlighting. This golf vehicle used molded-in-color polypropylene panels—completely eliminating the need for a traditional paint shop. The results? Massive cost savings, enhanced durability, and impressive impact resistance.
When Tesla hints at using similar techniques for its future vehicles—like the Cybercab—it’s not a brand-new concept. It’s an intelligent application of proven technology. This plastic-based construction method reduces weight, resists dents, and removes entire manufacturing steps, aligning perfectly with lean design principles.
Carbon Fiber: From Aerospace to Automobiles
Carbon fiber may sound exotic, but it’s been around for decades in aerospace and supercars. Munro & Associates helped Boeing with the 787 program by applying lateral thinking and lean manufacturing principles. The result was a lighter, easier-to-assemble aircraft that still meets extreme safety and performance standards.
These same principles are now appearing in EV body designs. Tesla’s newer models—including its Cybertaxi prototype—appear to use carbon fiber panels for strength, durability, and weight savings. But not all carbon fiber is created equal, as showcased by these various formats:
- Prepreg Layups: Used in the BMW i3 (2014), these offer strong, rigid structures but require costly curing processes.
- Resin Transfer Molding (RTM): Allows for complex shapes and fast production.
- Sheet Molded Compound (SMC): As used by CPC (Mitsubishi Chemical), SMC enables mass production of strong, shapely parts from carbon fiber-infused material.
Predicting the Next Automotive Design Innovation: One-Piece Castings and Puzzle Molds
Looking beyond just materials we must consider innovations in structure and assembly. Tesla and Chinese automaker Chery are already experimenting with massive one-piece castings that replace dozens of smaller welded parts. Not only does this reduce labor and complexity, it improves strength and consistency.
For manufacturing longevity, Munro recommends puzzle molds—more expensive up front but offering triple the lifecycle of traditional molds. It’s a classic lean manufacturing trade-off: pay a bit more now to save a lot later.
Textile Machines and Structural Parts: The Knitting Revolution
If you can change the rules, you can change the results. It may be surprising to consider knitting machines as a potential revolution in automotive structures. By shaping high-strength textiles like a sock and then injecting them with resin, manufacturers could produce shock towers and landing gear components with unprecedented strength and flexibility.
While this method remains underused due to economic disruptions like COVID and conservative manufacturing mindsets, the promise remains.
Scrap to Shine: BMW’s Sustainable Roof Innovation
One of the most surprising teardown insights came from BMW’s i3 roof panel. Made from scrap carbon fiber, it demonstrates how waste materials can be reengineered into high-performance, visually appealing components using resin molding.
This approach not only reduces cost and environmental impact—it also proves that sustainability, luxury, and innovation can coexist in modern automotive design.
Cost Analysis: When Carbon Fiber Becomes Cheaper Than Aluminum
A common argument against carbon fiber is cost. But here’s a game-changing truth: when carbon fiber drops to around $6–7 per pound, it becomes cheaper than fiberglass and comparable to aluminum—especially when measured by volume, not weight.
This challenges the outdated assumption that carbon fiber is too expensive for mass-market vehicles. As production scales and processes improve, it may soon become the default material for strength-critical EV structures.
Actionable Takeaways
- Molded-in-color plastics reduce costs, eliminate paint shops, and enhance durability.
- Carbon fiber has already proven its worth in aerospace and supercars—it’s ready for wider EV adoption.
- Sheet molded compound (SMC) allows complex shapes and large panels at scale.
- Puzzle molds extend tooling life, reduce downtime, and improve cost-efficiency.
- Knitted composites could redefine how structural parts are made—if the industry embraces the shift.
The Road Ahead: Innovate or Fall Behind
What unites these examples is a challenge to traditional thinking. We here at Munro don’t just analyze vehicles—we deconstruct entire industries. The lesson is clear: innovation doesn’t always mean new. Sometimes, it means recognizing overlooked technology and deploying it better than ever before.
Explore More Teardown Insights from Munro
Stay ahead of the curve with more teardown reviews, cost analyses, and engineering breakdowns from Munro. Dive deeper into EV design evolution, discover expert reviews, and learn how lean design is shaping the vehicles of tomorrow.