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