BAK MX4 (Gen 3) Tonneau Cover
Product Manager Q&A with David Germano

Q: What was the primary design philosophy behind the BAK MX4 (Gen 3), and how does it build upon previous generations?

A: Our primary design philosophy was straightforward: how do we take the best-selling truck bed cover in the world and make it even better? MX4 has been an extremely successful cover that truck owners have loved from the moment it launched; however, it’s been mostly unchanged since its introduction and was ready for several key product advancements. We revisited almost every part and system on the cover, and nearly every single component was re-engineered in some fashion. We really wanted to keep the things that made MX4 the best while improving the recurring frustrations along the way

Q: What were the biggest challenges faced during the design and development process of the BAK MX4 (Gen 3), and how were they overcome?

A: The biggest challenge we faced was the sheer breadth of the redesign. MX4 (Gen 3) is compatible with over 70 different vehicle applications, with each truck bed providing its own unique set of challenges to solve. In order to overcome these challenges, we invested in our Product Development teams and armed our Engineers with the latest tech to help them do their jobs. The Engineers were able to use computer modeling and finite element analysis to rapidly iterate through different designs digitally before committing to tooling new parts. We have multiple types and styles of 3D printers in our R&D Center to help speed up prototyping and check the fit of parts faster than before. Additionally, we have a fully stocked internal fabrication and prototype shop where we can build nearly anything to test out new ideas quickly. Each of these tools helped the design progress faster and the end product get better and better as we went along.

Q: How did customer feedback and market research influence the design decisions for this new iteration of the BAK MX4?

A: Customer feedback was critical to our design decisions for (Gen 3). We conducted qualitative research studies, met with consumer focus groups, gathered feedback, and interviewed consumers, dealers, and distributors, then pretty much consumed every review we could find at online retailers, truck owner forums, and video reviews.  

What this showed us was that we had a product that was generally loved but still had room for improvement. We took all those data points and then distilled them down to build clear targets for our Engineering and Design teams to aim for, so we knew we would build something that really resonates with users and truck owners. 

Q: Can you elaborate on some of the materials chosen for the BAK MX4 (Gen 3) and why they were selected for durability and performance?

A: Our most used material is a heavy-duty aircraft-grade aluminum. It’s the base material used on all of the side rails that attach to the bed, the structural frame around the cover’s panels, and for the skin on the panels themselves. This offers exceptional strength, without too much unnecessary weight.  

Elsewhere, we re-engineered the rubber material of the seals along the sides and the corners at the tail to be a rigid but flexible TPV, which is essentially a blend of rubber and plastic, giving us much more durability and a more consistent appearance than before. More importantly, this material lets us mold the rear corners directly into the side seal as one continuous piece. Previous MX4 generations had a plastic cap at the rear that became a potential breaking point and source of frustration

Q: What rigorous testing processes did the BAK MX4 (Gen 3) undergo to ensure its longevity and resistance to various environmental conditions?

A: The BAK MX4 (Gen 3) cover has been our most tested product to date. We conducted over 7500 hours of laboratory and real-world testing, checking everything from security and prevention of break-ins, water tightness, making sure it can open and close thousands of times without wearing down, checking what happens in common misuse situations, and ensuring dent/scratch durability, just to name a few.  

Regarding severe environmental conditions, we’ve tested the MX4 (Gen 3) cover to extreme temperatures from -40°F to 180°F and up to 95% humidity to ensure it is both tough enough for truck owners and something we are proud to put the RealTruck name on.

Q: What new features or enhancements were incorporated into the MX4 (Gen 3) to improve its functionality and ease of use for truck owners?

A: The biggest functionality improvement we made here was making the cover faster to install. We updated both how the side rails attach to the truck bed and how the cover itself attaches to the side rails. The side rails have new clamps that click in place to simplify holding the side rails on the bed while you tighten the bolts. In older versions, it sometimes felt like you needed three hands to hold the rail, the clamp, and a wrench. We also improved the bracket that attaches the cover to the rails. Rather than a fistful of nuts, bolts, and washers on Gen 1, it’s now a clamp that slides in place and is hand-tightened. Both improvements combine to make the installation measurably faster than the original MX4. 

Q: How does the design address common pain points or inconveniences experienced with other truck bed covers on the market?

A: In addition to the faster installation I mentioned above, we improved the ease of use by updating many of the parts of our latching system. The pull release cables now operate smoothly, and we specifically shaped the jaw of the latch to interact better with the side rails, making them securely close with less effort.  

This is not new for (Gen 3), but one of the features that separates MX4 from the competition is that the 3^rd brake light remains visible when the cover is flipped up and fully open. Others will stand straight up and block the brake light and brake light-mounted cameras, but the MX4 is specifically designed to tuck underneath, keeping the light visible and the cameras unobstructed. 

Q: How was the aesthetic design of the BAK MX4 (Gen 3) approached to ensure it complements the look of a wide range of trucks?

A: Aesthetics are a huge part of what has made RealTruck's BAK MX4 the best-selling truck bed cover in the world, so it was something we really had to be sure we didn’t mess with too much in this redesign. We kept the same matte finish appearance on our panels but refined the look in a couple of key spots. First, we hid the hardware that attaches the cover to the side rails to clean up the look of the top of the cover near the cab of the truck. Second, molding the tail corners into the side seal at the rear to again elevate the overall fit, feel, and finish. Our Industrial Design team created several versions that we laid up against many of our top-selling trucks to land on shapes that complement the truck bed.

Q: What considerations were made for seamless integration with existing truck accessories or modifications?

A: Over the last several years, truck manufacturers have really added more and more functionality and features into the tailgate. We wanted to ensure that MX4 Gen3 would work with all of them and not impact the function that, in many cases, truck owners paid a premium for. This includes things like powered-up and down tailgates, the multi-pro GMC/Chevy tailgates, and the split tailgate from RAM and Ford. Truck owners went out of their way to add these options, so their bed cover should work with them seamlessly 

Additionally, we also wanted to make sure we didn’t cover the truck’s stake pockets, so they are clear and available for the countless other accessories that rely on stake pocket mounting locations. This is something that MX4 has always done, but we felt it was important to maintain this clearance to let truck owners use the bed to its fullest. 

Q: Are there any future design iterations or accessory developments planned for the MX4 platform?

A: MX4 is a critical part of our future strategy at RealTruck. It’s been a massively successful product and is a platform that we plan to build around to create a truly great lineup with several models and feature sets that resonate with truck owners.  

This April (2025), we launched MX4 TS, which takes all of these new great MX4 (Gen 3) features and adds integrated T-slot rails for easy rack compatibility, allowing you to add racks, carriers, and other accessories. MX4 TS also features our Multi-Shield protective coating, which defends against everyday scuffs and scratches and increases durability by 11 times. The early feedback from MX4 TS has been overwhelmingly positive, and we are really excited to watch that product continue to grow and take hold in the market 

On top of that, we have our most technology-packed version of MX4 launching towards the end of this year. I won’t go into too much detail quite yet, but rest assured, it will be a big step forward for MX4 and for Hard Folding Covers in general.  

Looking further out, we have several truly industry-changing technologies in development that we expect to launch in the coming years. All in all, we want MX4 to continue to lead the way for all of our truck bed covers.