Interior Design

Components

Design Rules

Design Methods

Environment

Panels

Center Console CFC

Door Panels

Instrument Panel IP

Roof Panel

Displays

Technologies

LED

Glove Box

Combi Cluster Area

Crash Rules

Ergonomy Rules

Optical / Haptical Rules

Manufacturing Techniques

Mounting

Molding

Joining

Fixed Joints

Fixation Techniques

material closure (long term)

Section conceptual design

form closure (short term)

Gaps

Offset continuity

two-shells-method

A-Shell

B-Shell

contains mounting-features

Development Process

A Clear Input

Requirements

Specifications

B Development

scheduled Deadlines

Budget

Time (working hours €/h)

Total (€/project)

Research

Calculation

Proposals

Building Modell

C Output

Comfort / Functional Rules

Physics

Chemics

Fluid Flow

Air Vents & air ducts

Steering Wheel

Gear Shifter

CAD

Factors

relevant for Fixation

relevant for Shape

Stress

Fabrication Methods

Tolerances: Fabrication<->Gaps

force closure

Welding

CAD 3D-Model (Assemly & Parts)

BOM (Bill of Materials)

CCB Cross Car Beam

HPDC - High Pressure Die Casting

Injection Moulding

HVAC - Heating Ventilation Air Conditioning

Center Stack / CID (Center Information Display)

Manufacturing

HPDC

Welding

Advantages

General Aspects to Consider

Tooling Directions / sufficient drafting

Undercuts / Sliders

Cliping

Threading + Screwing

Bolts

Kinematic Connections

Screw Nut

Easy-Boss + Retainer

Alpha-Clip + Retainer

Clearence Holes

Screws

Standard Unified Threads

Screw types

Vitol-Element (tolerance compensation)

Order of Assembly

IP

Body-Shell ◄ CCB ◄ IP Carriers ◄ Function Carriers ◄ Function Devices ◄ Covers / Bezels

M6

M4

Standard Nut Types

for plastic

for metall

for reinforced materials

Function Carriers

Display Carriers

M8

Airvent flow density

Mechanical

Stiffness

Stability

Omega Clip

one-sided

two-sided

Casing In

Standard

TP 40

Bonding

Arm Rest

Decor Components

Chrome Trims

Special Conditioning

Graining

Forming & Cutting

Bending

Welding Aspects

Design Aspects

Offset from A Surface

plus Trimming Surface

can be part of a gap between part and environment surface

X Gap

visible surface

Z Gap

triming surf ace is part of gap : and offset from environment

trimming surf ace is not part of gap : offset from part A Surface

Snap-fitting

General Rules

min. thickness ➖ 0,8mm

min. rip root-thickness ➖ 1,2mm

min. draft angle at touch-up area ➖ 7°

hook - snapping geometry

holding geometry

casing geometry

holding geometry

min. gap static ➖ 1mm

min. gap kinematic ➖ 3mm

min. radius A Surfaces ➖ 5mm

min. draft angle ➖ 1°

Cross-Car-Beam

Fixation HUD

Function

Support

IP Panels Assembly

Footwel panel

Function Carriers

Glove Box

HUD

Jointing Components

Stamped and bent parts

link to

Car Body

Front Wall

Side Walls

Tunnel

HVAC

Stamping

Stamping and Bending

Technologies

Joint Types

Materials

Magnesium

Materials

Aluminium

Cast Iron

Screw Boss

Butt Joint

Corner Joint

Edge Joint

T- Joint

Sheet metal

ultrasonic-welding

WIG

MSG

buttweld types

I

K

V

X

Y

U

Fillet weld

concave weld

convex weld

mittre fillet

click to edit

Lap Joint

Time Table

Part Drawing & Specifications

Surface Design

SolidDesign

Sheet-Metal Design

Fabrication Method

Used Materials

Environment

Assembly Methods

Advantages

click to edit

Disadvantages

poor tolerances

MAG

MIG

Scarf Joint

click to edit

Accesibility

Carrying capacity

Free from notches

Internal stress

Verifiability

Parting Line

Feasability

Parts Clearence

1mm

3mm

Manufacturing process adaptation

Radii

2,5mm

1mm

5mm

Radii

Glue Contact Surface width

2mm

Leather

Seams

Band seam

Foam

Coating / Finishing

Foaming

Leathering

Graining

OLED

Vacuum Leathering

Flush / Foaming

Carrier manufacturing specific design

Run Off = 15-20mm

Foaming process

Vacuum Groove

Isolation

Inflatable seal

Diameter = 14mm

preferable r_min = 17,5 / R=25 (frimo)

minimum radius = 12,5 (frimo)

Delta Bead

Skin manufacturing design

Seal + Vacuum Groove + Cleaence >> Run Off = 35mm

Mixed Techniques

C-Clip

Welded Nuts

Vacuum Access Conic Cutouts

r=0,4 mm/ R=1mm / d_H=55mm / d_V=35mm

in tooling direction (molded parts)

Flock Coating

Ejection surfaces

Management

Monitoring

Time Table

Task-tracker

Checklist

Analog

I_Cluster

Bezel

Carrier

Belly Trims DS/PS

Footwell Trims DS/PS

Carrier

Inner & Outer Lid

Gear System

Center Stack Area

Carrier

Deformation Elements

Top Pad

Main Carrier

Chroming

Concept Solid Design

LOP

Carrier

Bezel

Trim

Trolley Duct

Inlet

Outlet

Side Curtain

composite construction

Press-Pinch