US company Worksport brings manufacturing in-house

An investment in a Prima Power PSBB line enables Worksport to manage its manufacturing processes flexibly

By reshoring manufacturing, US-based Worksport Ltd has boosted efficiency, improved product quality, and expanded its ability to build advanced truck covers and clean energy solutions at scale. In an era where reshoring is becoming more than just a trend and is being viewed as a necessity — Worksport is proving that American manufacturing innovation is alive and well. The company is known for its disruptive approach to truck bed cover systems, tonneau covers, and its energy-forward products like SOLIS and COR.

Based in Buffalo, New York, Worksport builds smart solutions for truck owners, from bed covers to portable solar systems. After initially planning to scale production overseas, the company made a big decision — to bring manufacturing in-house and take full ownership of how its products are made. The shift was not just about cost, it was also about control, quality, speed, and vision; and that vision started with a challenge — how to produce better covers, closer to home, and with long-term scalability in mind.

The company made the decision to build a new facility in West Seneca, New York, was not just built — it was re-imagined from the ground up. Worksport COO Chris Bernaudo, said: “We wanted to automate as much as possible from day one. Not to eliminate people, but to eliminate human error — it is about consistency and quality.”

That philosophy led to Worksport investing in a PSBB line supplied by Prima Power’s. Mr Bernaudo added: “We were not looking for manual benders. We had a design in mind and were looking for the best solution. Other suppliers offered cells — but we needed a full line and Prima Power was the only manufacturer that came close.”

The ‘heartbeat’ of the facility
Beyond technical capability, support played a major role. Fred Winter, the lead PSBB operator, said: “Prima Power’s responsiveness and service really sealed it for us. Any time we have had issues, the team is right there with us. Furthermore, the support and training have been top-notch.”

Installed and operational within a year, the PSBB line now acts as the ‘heartbeat’ of the facility. Mr Winter added: “We can run coil to panel in under 5min. It is incredibly efficient — especially with over 90 different products requiring custom lengths.” That speed translates into strategic agility, as Mr Winter explained: “Our operation is basically built around the Prima Power cycle time. It sets the pace for everything else.”

The integration has not just improved throughput, Worksport has reduced material waste, enhanced quality, and gained confidence in repeatability. Mr Winter said: “We even modified some parts of the machine to handle our delicate painted material. Now it runs clean, consistently and even overnight.”

Despite being built around automation, Worksport’s culture is anything but cold. Mr Bernaudo continued: “The goal was never to replace people. Automation frees them to focus on higher-value tasks — and that builds pride.”

Mr Winter, who joined the company when it had just four employees, agreed: “This machine made me love sheet metal. We have got the Ferrari of machines here.” From training to troubleshooting, the Prima Power system has empowered the team to learn and grow. He continued: “We have dealt with every kind of issue — sensor problems, encoder cables, you name it. Now we feel confident, and the Prima Power team helped us learn and adapt every step of the way.”

Built with the end user in mind
With operations growing and hiring ramping up (from 60 to over 120 by year-end), Worksport is executing a clear vision. Mr Bernaudo said: “We are growing aggressively, but not impatiently. We are doing it step by step.” That includes elevating truck bed covers to a new standard. He added: “Our competitors have lowered quality. We saw that and said: 'We can do better’.” Worksport’s products are built with the end user in mind — from thicker aluminium panels to smart, functional designs that hold up over time.

Plus, it is all now made in the USA — something investors, customers, and employees can buy into. Mr Bernaudo continued: “This facility used to be a beer distribution centre. Now it is where we make the most advanced truck bed covers and power systems in the market.”

WorkSport is not stopping at covers. Mr Bernaudo said: “We are building a full power ecosystem. The truck cover is just the start. Our solar-integrated cover and modular battery system open the door to adventure, independence, and energy freedom.”

From off-grid film crews to weekend overlanders, Worksport sees its future ‘in powering mobile life-built on the backbone of rugged, intelligently designed truck accessories’.

Mr Bernaudo concluded: “It is not just about trucks. It is about what trucks enable. We are giving our customers the tools to go further and do more.” At the centre of that journey is a bold investment in manufacturing — and a technology partner in Prima Power.