Integrated Punching, Shearing and Bending Line Allows Worksport to Reshore

Worksport Ltd. is known for its disruptive approach to truck-bed cover systems, tonneau covers and clean-energy products such as portable solar systems. After initially planning to scale production overseas, the company made a pivotal decision: bring manufacturing inhouse and take full ownership of how its products are made. This decision challenged Worksport on how to produce better covers closer to home and with long-term scalability in mind.

"Originally, we were going to grow manufacturing in China," says Chris Bernaudo, Worksport COO. "Then we raised triple what we expected, and everything changed. We shut the curtains, built a new type of company, and brought it all home."

Resulting from this decision, the company's West Seneca, NY, was reimagined from the ground up.

"We wanted to automate as much as possible from day one," Bernaudo explains. "Not to eliminate people, but to eliminate human error. It's about consistency and quality. The goal was never to replace people. Automation frees them to focus on higher-value tasks, and that builds pride.”

The centerpiece of the inhouse-manufacturing and automation decisions: installation of a Prima Power PSBB (Punching+Shearing+Buffering+Bending) line.

"We weren't looking for manual benders,” says Bernaudo. “We had a design in mind and were looking for the best solution. Other suppliers offered cells but we needed a full line. Prima Power was the only one that came close."

The PSBB automatically processes blank sheets into ready-bent, high-quality components. Material flow can be arranged in flexible ways—transfer parts directly to automatic bending, balance the different time requirements of bending, punching and shearing, and exit material from the PSBB while bringing in new material. Versatile buffering ensures optimum operation of the integrated machines in terms of manufacturing cost and throughput time, whatever the manufacturing task at hand, offer Prima Power officials. Specifically, the line integrates servo-electric punching, shearing and bending; automatic, flexible material flow; and sophisticated software.

The PSBB line now acts as the heartbeat of the facility, according to Winter. "We can run coil to panel in less than 5 min.,” he says. "It's incredibly efficient, especially considering that we have more than 90 different products requiring custom lengths. Our operation basically is built around the line’s cycle time. It sets the pace for everything."

The integration hasn't just improved throughput. Upon adding the PSBB, Worksport has reduced material waste, enhanced quality and gained confidence in repeatability.

"We even modified some parts of the machine to handle our delicate painted material," Winter says. "Now it runs cleanly and consistently, even overnight. This machine made me love sheet metal. We've got the Ferrari of machines here."

With operations growing and hiring ramping to an expected 120-plus employees by the start of 2026, Worksport is executing a clear vision. "We're growing aggressively, but not impatiently," says Bernaudo. "We're doing it step by step. This facility used to be a beer-distribution center. Now it's where we make the most advanced truck bed covers and power systems in the market."

Adds Winter: "We bring people through the factory and they stop at the PSBB. It's the showpiece. It's the proof that we're serious."

See also: Prima Power North America, Inc.

Technologies: Bending, CNC Punching, Management

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