Engineering

Based on thorough market and benchmark analyses we develop concepts for new products and draw up product requirements documents in close cooperation with our customers.

We draft various possible component concepts, propose materials, component separation and installation space, validate the concept in a pre-development phase and determine feasibility in conceptual studies and preliminary analyses.

We verify the design on technical criteria, assess and validate the design - in close cooperation with the customer - up to and including the design freeze.

We verify the technical implementation of the functionality in the concepts – also under cost aspects.

We verify the functionality, ease of use and ergonomics of the designs.

We use high-precision simulation tools to verify that the finished components will be in compliance with all relevant legal requirements, including vehicle safety, to guarantee type approval.

We analyse the various component concepts with respect to the tolerances that can be expected in each case. Based on the analysis results, our team determines the clearances within and between the components and the manufacturing processes that assure achievement of the intended functions.

We test the functions of the components and validate courses of motion using CAD software and 3D kinematic examinations.

We render 3D data for defined milestones along the design process, from the concept up to and including the engineered product, taking into consideration the number of items to be produced, and the tooling and material-specific requirements.

Risk analyses using APIS IQ software avoid errors and enhance the technical reliability of the design.

We perform FEM calculations (Hyperworks), tests to determine the forces occurring during assembly/disassembly, calculations of the component rigidity, misuse tests and component validations.

We test the components to verify that the design is suitable for the intended production process and to determine their demoulding behaviour, shrinkage, distortion and filling characteristics (using Moldflow simulation software, for example).

The individual components within a module are collision and clearance tested.

We provide

• Drawings of parts and modules, exploded assembly drawings, part lists, assembly and installation manuals,
• Drawings to customer specifications,
• Assembly and welding concepts, and
• Part lists.

We design and engineer testing, measuring, assembly and joining equipment (welding, bonding, etc.) for automotive series production.

We provide support in tooling and process optimisation, modification and data management, and cost reduction.

Using experience from initial components and data from subsequent tests, we optimise production costs, component strength, weight, ease of assembly, etc.

We provide documentation of design modification and component lifecycle reports inc. data transfer documentation.

Physical component testing: material tests, environmental resilience testing, functional testing.

We define assembly and installation concepts and the geometrical layout of the components to meet the requirements of the planned joining methods.

Diagrams and CAD drawings provide realistic and photorealistic product images.

We scan and digitise components, modules and complete vehicles in our in-house metrological facilities.

We prepare product and process documentation during all project stages (part lists, operating procedures, flow charts, etc.) During the design process we take over supplier management.

We verify the feasibility and process reliability of the component geometries in comprehensive tests.

We optimise the product data in order to maximise tooling life, avoid process variations and assure a consistent product quality.

We perform rheological analyses, including mould-filling simulations, of complex injection-moulded parts to analyse their distortion and shrinkage behaviour.

We design injection-moulding tools based on 3D product data provided by the customer, taking tooling and product requirements documents into account. Our services include 3D designs, process-specific drawings of individual components, part lists, documentation and maintenance schedules.

We adapt 3D tooling designs based on modified product data, drawings of revised designs, and documentation data.