BASENOR engineer 3D scanning Tesla Model Y Juniper center console for armrest storage box development

Design Story

How We Engineered the World's First Dual-Layer TPU Armrest Storage

2 months. 5 prototypes. One material science breakthrough. Inside the making of the CA390 for Tesla Model Y Juniper & Model 3 Highland.

The Problem

Every Armrest Box on the Market Felt the Same—Because They Were

When Tesla redesigned the Model Y Juniper and Model 3 Highland center console, they left the armrest storage as a single open cavity. Useful, but not organized. Within weeks, aftermarket brands flooded the market with storage inserts—and they all looked identical.

We ordered a dozen competitors. Same factory. Same ABS plastic. Same loose fit with visible gaps. Pick one up and it feels hollow, cheap, temporary. Drop your keys in and you hear them rattle against hard plastic all day long.

"We didn't want to make another $12 box that people settle for. We wanted to make the one they actually recommend to friends."

So we asked ourselves a different question: what if the material itself could solve the problem? What if instead of hard-on-hard contact, we could create a surface that actually protects what you put inside?

That question led us to TPU—and to a two-month engineering journey we didn't expect.

Precision First

3D Scanning the Console—Down to 0.02mm

Before designing anything, we needed to understand the exact geometry of the new center console. Not from spec sheets—those don't capture the subtle draft angles and parting-line offsets of injection-molded interiors. We needed reality.

Our team brought a handheld structured-light 3D scanner into a 2025 Tesla Model Y Juniper. The blue laser grid captures surface topology at 0.02mm resolution, building a point cloud of the armrest cavity in real time.

3D laser scanning Tesla center console with blue structured light pattern — Structured-light scan of the center console cavity

Handheld 3D scanner capturing Tesla armrest box cavity dimensions — Capturing every contour of the armrest pocket

Overhead view of 3D scanning Tesla Model Y Juniper center console — Overhead scan—mapping the full console profile

The scan revealed what calipers alone would miss: the cavity isn't a perfect rectangle. It has 1.5° of draft on the long walls and a subtle radius at each corner. Competitors who design from 2D measurements end up with boxes that rock or float—ours sits flush because we designed to the actual surface.

The Innovation

ABS + TPU: A Dual-Layer Approach Nobody Had Tried

Standard armrest inserts use one material: ABS or PP plastic. Rigid, cheap, done. We chose to combine two: a structural ABS outer shell for dimensional stability, and a TPU (thermoplastic polyurethane) inner layer for scratch protection and vibration damping.

ABS Outer Shell

Provides rigidity and holds the precise shape captured by our 3D scan. Carbon fiber texture finish matches Tesla's interior aesthetic.

TPU Inner Layer

Soft-touch surface that cushions items on contact. Absorbs vibration so keys, coins, and sunglasses stay silent on the road.

Anti-Slip Texture

Micro-groove pattern on the TPU prevents items from sliding during acceleration, braking, and turns.

Eco-Certified

Both materials are REACH and RoHS compliant—no off-gassing, no chemical smell, safe for cabin air quality.

3D scan visualization of BASENOR CA390 armrest storage boxes in Tesla center console — 3D scan model — dual storage boxes in the center console cavity

3D scan detail of CA390 organizer compartments with BASENOR branding — Close-up of the organizer compartments and BASENOR branding

3D scan of CA390 precision-fit compartment showing segmented layout — Precision-fit compartment — designed from 0.02mm scan data

This was, to our knowledge, the first armrest storage box to use a dual-layer TPU construction in the Tesla accessory market. No reference designs existed. No supplier had tooling experience for this approach. We were writing the playbook ourselves.

Trial & Error

5 Prototypes, 1 Material Science Breakthrough

Our first prototype was 3D-printed in ABS and tested in-vehicle within a week of receiving the scan data. Fit was close—but "close" isn't a product.

BASENOR CA390 3D printing timelapse on Bambu Lab printer — from empty bed to finished prototype in 16:9 widescreen — Rapid prototyping: 6-hour 3D print captured in a timelapse on our Bambu Lab printer

Prototype A — First Physical Fit Test

3D-printed ABS shell, installed in our test vehicle. Marked "M3 MY CA390-A" by hand. Caliper check showed 192.91mm width—within spec, but lateral play of ~0.8mm was noticeable by touch.

Prototypes B & C — Dimensional Refinement

Adjusted wall thickness and corner radii. Prototype B eliminated lateral play. Caliper verification confirmed sub-0.3mm tolerance across all critical dimensions.

Prototype D — The TPU Shrinkage Problem

When we moved to injection-molded TPU for the inner layer, parts came out 2-3% smaller than designed. TPU shrinks as it cools—but unlike ABS, the shrinkage rate varies with wall thickness. Our dual-layer geometry made this unpredictable. Three batches failed dimensional checks.

Prototype E — Final Production Version

Solved the shrinkage problem by adjusting the TPU material compound—modifying the ratio of hard to soft segments in the polymer chain. This gave us a predictable, uniform shrinkage rate that we could compensate for in the mold design. Final parts hit target dimensions first shot.

Prototype A

Visible lateral play. Handwritten "CA390-A" for tracking.

Prototype B (Refined)

CA390 Prototype B installed with improved fit

Flush fit. No movement when pressed.

"TPU shrinkage nearly killed this project. Every supplier said 'just add 2% to the mold.' But with dual-layer walls of varying thickness, uniform scaling doesn't work. We had to reformulate the material itself."

Verification

Caliper-Verified, Road-Tested

Every prototype was measured with digital calipers and installed in our 2025 Tesla Model Y Juniper test vehicle. We don't rely on CAD simulations alone—real-world fit is the only metric that matters.

Digital caliper measuring CA390 Prototype A dimensions — Prototype A width: 192.91mm

Digital caliper measuring refined Prototype B — Prototype B: refined to sub-0.3mm tolerance

Final validation of CA390 in Tesla Model Y Juniper center console — Final validation: prototype sits perfectly flush with the console surface

The final prototype passed a 500-mile road test. No rattles. No shift. Items placed in the TPU-lined compartments stayed exactly where they were put—through highway driving, hard braking, and spirited canyon runs.

Materials

Why We Chose What We Chose

Component	Material	Why
Outer shell	ABS with carbon fiber texture	Rigid structure, Tesla-matching finish, UV resistant
Inner lining	TPU (custom compound)	Scratch-proof, vibration-absorbing, eco-certified
Dividers	ABS + TPU contact edges	Organizes space without scratching items
Base pad	Anti-slip micro-groove TPU	Prevents sliding under all driving conditions

We specifically avoided common cost-cutting materials: no PVC (off-gasses in heat), no recycled PP (warps over time), no flocked fabric (peels after 6 months). Every material choice was made for the life of the vehicle, not the price of the BOM.

The Result

What You Actually Get

Feature	What It Means for You
Dual-layer ABS + TPU	Your sunglasses, phone, and keys don't get scratched
0.02mm scan-derived dimensions	Sits flush with zero wobble or gaps
Carbon fiber texture	Matches Tesla's interior design language
Segmented compartments	Everything has a place—no more digging around
Anti-slip micro-grooves	Items stay put during hard braking and turns
Tool-free install	Drop in, done. Under 10 seconds.
REACH & RoHS certified	No chemical smell. Safe cabin air.
Fits Model 3 Highland + Model Y Juniper	One product, two vehicles. Same precision fit.

Common Questions

Frequently Asked Questions

Does this fit both Model 3 Highland and Model Y Juniper?

Yes. Both the 2024-2026 Tesla Model 3 Highland and 2025-2026 Model Y Juniper share the same center console armrest cavity dimensions. The CA390 is 3D-scanned and validated for both vehicles.

What makes the TPU inner layer different from regular plastic?

TPU (thermoplastic polyurethane) is a flexible, rubber-like material that absorbs impact and resists scratching. Unlike rigid ABS or PP plastic, it won't scratch your sunglasses, phone, or keys. It also dampens vibration, so items stay silent while driving.

Will it rattle or move around while driving?

No. The CA390 is designed from 3D scan data with sub-0.3mm tolerances. It sits flush inside the armrest cavity with no lateral or vertical play. We road-tested it over 500 miles including highway and canyon driving with zero rattle.

How do I install it?

Simply open the armrest lid and drop the storage box in. No tools, no clips, no adhesive. The precision fit holds it in place. Installation takes under 10 seconds.

Does it block the USB-C ports or wireless charger?

No. The CA390 is designed with cutouts that preserve full access to the USB-C charging ports. It does not interfere with the wireless charging pad or any console functionality.

What is the carbon fiber texture? Is it real carbon fiber?

The outer shell features a carbon fiber weave texture molded into the ABS plastic. It's not actual carbon fiber, but a high-quality textured finish that matches Tesla's interior aesthetic and provides a premium look and feel.

Is the material safe? Any chemical smell?

Both the ABS and TPU materials are REACH and RoHS certified, meaning they contain no harmful substances and produce no off-gassing. There is no chemical smell out of the box—we specifically chose materials rated for automotive cabin use.

What was the biggest engineering challenge?

TPU material shrinkage during injection molding. As the world's first dual-layer TPU armrest storage, we had no reference data. The TPU shrank 2-3% unevenly across different wall thicknesses. We solved it by reformulating the TPU compound to achieve a uniform, predictable shrinkage rate—a process that took three material iterations.

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The Armrest Box That Took 5 Prototypes to Perfect

Dual-layer TPU construction. 3D-scanned precision. Carbon fiber finish. Designed for Tesla Model Y Juniper & Model 3 Highland owners who notice the difference.

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