Waycon Manufacturing recently partnered with Edison Motors to build a custom Hybrid Electric Truck Cab. This project demonstrates how local fabrication and close collaboration can turn a complex design into a working prototype.
A New Approach to Truck Cab Design
Edison Motors approached Waycon with a unique challenge: build a lightweight custom truck cab for their new hybrid electric drivetrain. Unlike traditional cabs, Edison’s design includes center seating for better driver visibility and unique front-facing dozer-style doors for easier access.
One-Stop Metal Fabrication: From CAD to Prototype
Full Cab Assembly: Waycon handled the custom metal fabrication of the entire shell, structural frame, exterior skin, doors, and interior panels. The team handled structural joints, reinforcements, precise fit-up, and alignment, excluding only the electrical and drive systems.
Sheet Metal Forming and Riveting: To minimize weight, the cab was constructed using light-gauge sheet metal. Welding wasn’t suitable for this material, so Waycon applied specialized forming and precise riveting methods to maintain strength and panel rigidity.
Custom Door Engineering: The unique front-facing dozer-style doors required custom hinge design, reinforced door frames, and exact alignment to ensure smooth and safe operation. Each door latch was engineered to meet CMVSS 206 and/or FMVSS 206 safety standards, ensuring compliance with strict vehicle safety regulations.
Window and Panel Integration: Complex window assemblies and interior panels were designed to optimize visibility and structural strength while allowing for straightforward installation of Edison’s hybrid components. The cab uses double-pane laminated glass with an AS-1 safety rating, providing enhanced durability and safety for the driver.
Surface Prep and Finishing: After fabrication, Waycon completed full surface preparation and primer coating in-house, ensuring the prototype was ready for final fitting and further component installation.
Continuous Design Support: Weekly reviews and direct collaboration with Edison’s team made it possible to resolve design challenges quickly and ensure the build matched project requirements at every stage.
The Value of Canadian Full-Service Manufacturing
For forward-thinking companies like Edison, working with a local, all-in-one manufacturing partner offers clear benefits:
Engineering Support — Our team of experts bridges the gap between CAD files and a buildable, cost-effective product.
In-House Fabrication — CNC machining, sheet metal cutting, forming, riveting, and finishing are all done in-house for tighter quality control.
Rapid Prototyping — Direct, ongoing collaboration means we can refine and deliver working prototypes faster than overseas or fragmented production models.
Project Outcome and Next Steps
With the prototype complete, Edison Motors is moving forward with system testing and refinements for its hybrid truck platform. Waycon’s support helped them meet a tight timeline and bring this new concept from digital design to a fully assembled cab ready for integration.
Made in Canada, Built for Tomorrow
The Edison Hybrid Cab highlights Waycon’s ability to build custom assemblies for innovative technology. The entire cab was fabricated in Canada with complete process control from design to final build.
Have a project in mind?
Contact Waycon to discuss how we can help bring your design into production.
