Custom Cargo Dump Bed Fabrication: A GEM Electric Vehicle Case Study

The Challenge: Sourcing a Turnkey Fabrication Partner

GEM’s design team had developed a concept for the cargo dump bed but needed a partner to handle plastic and structural metal fabrication, hardware integration, and final assembly. Procurement teams comparing custom metal fabrication companies to plastic-only vendors, or vice versa, face the same tradeoff: turnkey suppliers mean fewer handoffs and less tolerance risk.

The Solution: Redesigning for Manufacturability

Before launching tooling or production, Aubright’s team conducted a thorough design-for-manufacturability (DFM) review of GEM’s original concept. Our consulting and design team worked with GEM’s engineers to refine component geometry and tolerance relationships. This upfront engineering phase ensured the multi-material assembly could be produced repeatably at high volume without compromising structural integrity.

From Contact to Production: Our Process

The project moved through a development and validation process spanning over a year, including the following stages:

• Scoping: Defined raw materials, hardware components, tight tolerances, and assembly requirements
• Quoting: Priced and scheduled based on confirmed specifications
• Purchase order: Formalized scope and schedule
• Design refinement: Adjusted the original concept for manufacturability
• Prototyping: Built functional samples for fit and function evaluation
• Customer approval: GEM reviewed and signed off before production
• Production: Transitioned to consistent weekly output

Our prototyping capabilities are built to catch fit and tolerance issues before they reach the production line.

Materials & Technical Specifications

The finished assembly combines four materials across its plastic and metal components:

• High-Density Polyethylene (HDPE): Used for the bed body; impact-resistant and weather-tolerant
• Thermoplastic Polyolefin (TPO): Applied to trim and facing components that require some flexibility
• Sheet Steel: Structural metal panels fabricated by Northern Metal Products
• Steel Tube: Frame and hinge support members for the dump mechanism

Measuring 47 in. L × 56 in. W × 18 in. H, the final assembly incorporates custom hardware, integrated hinge mechanisms, and a durable powder-coated steel finish into a single, ready-to-install unit. With our unified plastic and metal fabrication model, we streamlined quality control across all four materials.

Managing Tight Tolerances Across Moving Parts

Because cargo dump beds have multiple moving parts, maintaining tight tolerances between flexible plastics and rigid steel frames on this project was critical. Components have to stay precisely aligned throughout regular use, load cycles, and temperature variation.

Managing tolerances across these two material types requires attention at the design stage and consistent controls through production. To meet this requirement, Aubright holds ISO 9001:2015 certification, which means documented procedures, traceability, and defined quality standards at each step. Our quality assurance and quality control processes are built around that framework.