WorkSport Reshores Its US Production with Prima Power’s PSBB Line

With full control of its US facility, Worksport 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 nearshoring is more than a trend Worksport is proving that American manufacturing innovation is alive and well. Known for its disruptive approach to truck bed cover systems, tonneau covers and its energy-forward products like Solis and COR, Worksport recently took a step to bringing manufacturing in-house.

Bringing manufacturing home

Based in Buffalo, NY, USA, 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 pivotal decision: to bring manufacturing in-house and take full ownership of how its products are made. "Originally, we were going to grow manufacturing in China," said Chris Bernaudo, 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."

The company's West Seneca, NY, facility wasn't just built-it – was reimagined from the ground up. "We wanted to automate as much as possible from day one," Bernaudo explained. "Not to eliminate people, but to eliminate human error. It's about consistency and quality." That philosophy led them to Prima Power's PSBB (Punching, Shearing, Buffering, Bending) line. "We weren't looking for manual benders. We had a design in mind and were looking for the best solution," said Bernaudo. 

Installed and operational within a year, the PSBB line now acts as the "heartbeat" of the facility. "We can run coil to panel in under five minutes," said Winter, the lead PSBB operator. "It's incredibly efficient – especially with over 90 different products requiring custom lengths."

That speed translates into strategic agility. "Our operation is basically built around the Prima Power cycle time," Winter says. "It sets the pace for everything." The integration hasn't just improved throughput. 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 said. "Now it runs clean, consistently – even overnight."

Empowering workforce through technology

Despite being built around automation, Worksport's culture is anything but cold. "The goal was never to replace people," said Bernaudo. "Automation frees them to focus on higher-value tasks – and that builds pride.” Winter, who joined the company when it had just four employees, agrees: "This machine made me love sheet metal. [...]"

"We're building a full power ecosystem," Bernaudo said. "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. 

(Source: Prima Power)