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Master's Certification in BIW Fixture & Plastic Design

Master's Certification in BIW Fixture & Plastic Design

  • 0% EMI Option Available
  • Pre-requisites : For Mechanical & Automotive Engineers
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Overview

1. Why should a student select this Master's program?


  • This Master's program is for students who are interested in working in with sheet metal in the domain of automobile engineering and are interested in designing and manufacturing plastic components in automobiles.

  • This Master's program gives students an edge over others as this program provides an industrial insight into how the BiW and automotive plastic trims are designed and manufactured 

 

2. Upon the completion of this Master's program, what are the job profiles that a student will become eligible for?


  • This program can help you get recruited as a BIW design engineer, a BiW fixture designer, Moldflow simulation engineer in plastic industries, Automotive plastics trims designer, in organizations around the world. 


3. What are some companies that recruit in this field?

  • This Master's program will help you find employment in organizations like; Techolutions, and major automotive OEMs.

Courses in this Master's program:

  • Advanced Sheet Metal Design
  • Automotive Sheet Metal Design using NX CAD
  • Automotive BIW Fixture Design
  • Moldflow and Polyflow Simulations for Injection Molding
  • Plastic Design Using CATIA v5
  • Mold Design using SolidWorks

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Course One: Advanced Sheet Metal Design

1Introduction

Sheet Metal application provides an environment for the design of sheet metal parts used in machinery, enclosures, brackets, and other parts normally manufactured with a brake press. Siemens NX CAD sheet metal design software incorporates material and process information in sheet metal-specific modelling features: bends, flanges, tabs, cutouts, beads, dimples, louvres, corner and edge treatments, patterns, and other formable features. You can also quickly convert solid models to sheet metal components, and create sheet metal parts that enclose other components. More than 85% of sheet metal industries use NX CAD as a design tool. 


In this course, you will learn the sheet metal module of NX CAD [UG NX] software. At the end of this course, you will be able to implement sheet metal design constraints. You will also be able to easily create real-time industry models of sheet metals. 

2Introduction to NX CAD Interface

In this module, you will learn how to create the sketches in NX CAD


  • Creation of lines, circles and squares
  • Specifying the dimensions
  • Pattern creation

3Introduction to Sheet Metal Modelling Interface

Understanding Tabs and Flanges

  • Contour flange
  • Advanced flange
  • Jog flange
  • Hem flange
  • Corners, closed corners, & overlapping corners in sheet metals

Adds a flange to an angle to a planar face and adds a bend between the two.

Creates a base feature by extruding a sketch along a vector, or adds material by sweeping a sketch along an edge or chain of edges.

Advanced flange

Joggles

Lightning Cutouts

 

4Conversion Wizards for Solid to Sheet Metals

In this module, you will get a thorough understanding of:

  • Edge rip

  • Convert utility

  • Cleanup utility

  • Reliefs 

  • Face optimization 

  • Forming sheet metal from solid

5Stiffening Features in Sheet Metals

In this module, you will gain experience in:

  • Beads creation

  • Dimple creation

  • Emboss creation

  • Mirror features

  • Feature patterns

6Creation of Flattening and Forming

In this module, you will get an understanding of

  • Neutral file data
  • Surface extraction 
  • Adjacent and tangent face selections 
  • Flattening & Thickening


Projects Overview


2. Automotive Sheet Metal Design using NX CAD

1Introduction

The Automotive Sheet Metal Design using NX CAD course provides an outline of the current Body in White (BiW) component design factors and detailed explanations about their significance to part function, cost, and reliability. In this course, the modern design methodology is examined, covering Design for Manufacturing and Assembly and how determining product end-use requirements is essential to creating successful contemporary products. 
 
Upon completion of this course, you will have a comprehensive understanding of the physical and theoretical design factors that must be considered during the creation of first-rate BIW components. You can start your career as a design engineer in any sheet metal domain and with 2 to 3 years of experience, you can become a full-fledged BIW engineer.
 
 

2Vehicle development cycle

This is an introductory session where students are introduced to the basics of automobiles along with different models of car bodies. Students will also learn about the different stages of vehicle development that a car will go through before reaching the customer. Students will also learn about the three years of development activity that precedes the development of an automotive model.

3Basics of Automotive Body in White

In this session, the student will be introduced to the basics of automotive BiW. The student will be introduced to the basics of steel and its properties in detail because steel is an important component used in the construction automobiles. The steps that are followed in the selection of the material will be discussed as well. Students will be given an introduction into cross-functional teams that exists in an organization, and the need to coordinate with them along with examples of master sections and 3D components of the parts for easy and clear understanding.

 


4Design Methodology of a Hood, Fender, Roof, Back Doors, and Side Doors

In this module, we will focus our attention on the Hood, Fender, Roof, Side doors, and Back doors. The design procedures for all the afore-mentioned parts can be summarized as follows.

 

  • Design Requirements
  • Functional Requirements
  • Regulations
  • Gap and Flushness Requirements
  • Safety Requirements

 

5Case study - Converting -Backdoor/Tailgate Inner Panel

In this module, we will present a real-life scenario where the effect of converting an inner panel from aluminium cast to the steel deep draw part is shown. Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:

 

  • Seal surface width was the same as the aluminium liftgate
  • Tailgate outer parting was maintained as the same
  • Liftgate thickness was modified
  • Gap and flushness were maintained

 

 

When you enroll in this course, you will be able to clearly understand these design parameters and the decisions that were made. In this case study, the design guidelines were set through a series of CAE simulations.

 

 

6Design of key mechanism - Lock and Striker

In this module, you will study the anatomy of a Locker and Striker mechanism. In order to be a successful product development engineer, it is very important to understand in detail the development process and design requirements for even the smallest component.

 

7Process and challenges with supplier manufactured parts: Case study

In this module, we will look at two case studies. Both of these studies focus on supplier manufacturing practices. We will discuss the design challenges faced by two Asian Automotive suppliers and then go over the solution methodologies


Hood Design


3. Automotive BIW Fixture Design

1Introduction

A welding fixture is used to position product parts for welding. This secures the geometry of the product parts. Accurate positioning is critical to the success of the weld and the quality of the final position of each part. In this course you will learn various welding process, how to create Fixture for the given BIW components, create 2D drawings for each parts of the fixture and create BOP and BOM for the complete assembly.

2Introduction to BiW-Fixture

  • Definition of BiW, Jigs, & Fixture
  • BiW-Nomenclature
  • Types of Fixtures & their applications
  • BiW stations & their uses
  • Basic terminologies

3BiW-Fixture Basics

  • Project activities
  • Different welding processes
  • 3-2-1 Principle
  • Body planes

4Pre-Design Processes

  • Design methodology

  • Structuring a design tree

  • Different types of fixture units

5Units Design-1

  • Different types of Pin Unit Design
  • Different types of Clamp Unit Design
  • Different types of Rest Unit Design

6Units Design-2

  • Dump Unit Design

  • Slide Unit Design

  • Base Unit Design

7Finishing the design

  • 3D-finish
  • Rough locators
  • Pneumatic routing
  • Valve banks & selection
  • Gun study
  • Sensors & selection

82D-Detailing Basics

  • Drawing templates

  • Angles of projection

  • Basic GD&T used in fixturing

  • Scaling & views

  • Various detailing patterns

92D-Detailing 1

  • Key Sheet detailing
  • Unit detailing
  • Child parts detailing

102D-Detailing 2

  • Child parts detailing continued

  • Material selections

  • BOM preparation

11Documentations

  • Design terminologies

  • Sequence sheets

  • Clamp validations sheets

  • Ergo-sheets

  • Poka-yoke

  • Fixture process sheet

  • Cycle time study


Projects Overview


4. Moldflow and Polyflow Simulations for Injection Molding

1Operation of Moldflow/Inputs and Outputs of the tool

It deals with the working of Moldflow software & amp; the inputs required for running the analysis. Types of analysis that can be executed for validating the Mold tool and for product development. 

2Creation of Nodes and curves tools associated with its creation

Designing in Moldflow (i.e.) how to create a node and various options used in the creation of nodes and in the same way line creation and surface creations are explained during this session.

3Creation of mesh/Mesh correction tools

Mesh is the main requirement for running the analysis. The part is segmented into small triangles and that is called as mesh Creation of mesh and mesh correction tools are explained during this session.

4Types of Meshing and its parameter

Different types of meshes are used, depending upon the part geometry. How to create the other meshes and parameters that should be taken are explained.

5Gate location, Fill, Flow and Warp

The module used for analyzing the part, that is, selecting the analysis depending upon the objective or requirement will be explained in this session. 

6How to set the process settings

For executing an analysis process setting plays the main role. The results vary because of this setting. This setting is also the input for the molding machine. An idea for the process setting is explained in this session.

7Result analysis for fill and flow

The output obtained infill and flow analysis are explained in detail during this session.

8Cooling circuit design

The cooling circuit plays the main role in maintaining the temperature inside the mold. Many features are there in the cooling circuit and how to design that design features are explained in this session. 

9How to setup cool analysis

For cooling analysis, different types of coolant and modifications are required to optimize the mold tool. All the settings details will be explained.

10Transient Cooling analysis

This is an advanced type of cooling analysis where the molding tool is also analyzed. The setup for this analysis is explained. 

11Analyzing the results

The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.

12Result interpretations

The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are discussed here.



Projects Overview


Course Five: Plastic Design using CATIA v5

1Basics of Plastic Design

It includes Basic plastic terminology, the Injection molding process, design guidelines of various features, Plastic defects and how to eliminate those during the design phase

2Part Design Workbench (Basics)

Covers basic toolbars in Part design workbench Sketches, Sketch-based features and Surface-based features, Transformation features. Surface-based features, Boolean Operations, Creating plastic part features, Navigation toolbars, and measurement tools.

3Part Design Workbench (Basics)

Surface-based features, Boolean Operations, Creating plastic part features, Navigation toolbars, and measurement tools.


4Surface Design Workbench

GSD Wireframe for creating a skeleton for the surfaces, GSD surfaces for new surface creation, GSD operations to modify the created surfaces. Advanced surface creation including sweep and multi-section surfaces, Surface continuity behaviors.

5Creating Power Copy

Introduction to Power Copy creation from Part design workbench, instantiating power copy in the real-time plastic model. 

6Adding Thickness to Styling Surface

Creating volumes from surfaces, How to create B side surface from the aesthetic surface, Creating closed volume checking draft analysis.

7B Side Features Creation

Adding attachment and strengthening features, Creating plastic part features like Rib, Boss, Gusset, Dog House using part design.

8Draft Analysis in Detail

Tooling analysis of plastic parts, finding out tooling direction of a part, eliminating undercut areas for easy manufacturability.  

9Complete Model Creation from Styling Surface

Creating volumes from A – Surface, reading master sections, adding B side features including locators, ribs, analyzing tooling feasibility issues.                 


Projects Overview


Course Six: Mold Design using SolidWorks

1Basics of Injection Molding / SolidWorks Modelling

This section will have you covered in terms of the following basic concepts 

  • Injection molding process and how it works
  • Plastic processing methods such as 
  • Rotational molding
  • Extrusion
  • Vacuum forming
  • Blow molding
  • Gas assisted injection molding
  • Mold cycle and the factors affecting it
  • Thermoplastics and Thermosets
  • Current trend in the industry
  • The types of plastics being used
  • The properties of these plastics and 
  • How to select them

For the uninitiated, we’ve also included a session on the basics of SolidWorks where we take you through

 

  • Basics of sketching
  • Basics of using features in SolidWorks

 

 

 


2Basics of Mold Design / SolidWorks Surfacing

  •  After getting a basic understanding of injection molding from the previous session, in this session we will jump into the technical side of designing the mold.

 

The topics we will be covering are:

  • How the product development process takes place in the plastic industry
  • Various departments in plastic manufacturing industries and the workflow
  • Parts of mold - core, cavity, guide pillar, sprue, register ring, guide bush, ejector pin,  return pin, spacer blocks, core plate, cavity plate, ejector plates, etc.
  • 2 plate & 3 plate molds
  • Drafts
  • Parting lines

 

In the SolidWorks session we will continue where we left in the previous session and learn about the various surface tools used for designing.

 


3DFM and Defects

In the third week, we will be covering more theory related to various concepts and terms used in mold design. The topics we shall cover are:

 

  • Concept of machine tonnage and learn how to calculate it
  • DFM study where we will look at various concepts such as  gate point, wall thickness, cores, tolerance, venting, ejector pads, inserts, ejector inserts, guide pillar, support block, relief, free play inserts,  multi-gate position and flow leader.
  • Various defects that may occur during the mold design process such as short shot, flash, weld lines, sink marks, blisters, jetting, burn marks, warpage, gloss differences, hesitation, overpacking and unbalanced flow.

 


4Parting Surface / Mold Design Tutorial 1

 In the fourth week, we will be understanding the theory behind parting surfaces. The topics that will be covered are as follows:

 

  • What is a parting surface is
  • Types of parting surfaces such as flat, stepped, angled and profiled parting surfaces
  • Example cases where we will try to understand how the selection of parting surfaces takes place
  • Matching drafts
  • Shrinkage 
  • Inserts 



Then in the SolidWorks session we will start with our first mold design tutorial. We will be covering on a simple plastic component and we will learn the following:

 

 

  • Doing draft analysis for the model
  • Creating parting lines
  • Creating shut-off surfaces
  • Creating parting surfaces
  • Create basic mold blocks

 


5Sliders and Ejection System/ Mold Design Tutorial 2

In the fifth theory session, we will be looking at the topic of sliders and ejection systems. The topics that will be covered are:

  • Need for sliders and their working. 
  • 2 general types of sliders - sliding split type molds and the angular lift pin type molds.
  • Methods of actuating the sliders such as finger cam, dog leg, cam track, spring and the hydraulic actuation
  • Concept of slider locking
  • Various types of ejector systems such as pin, sleeve, stripper and blade ejector systems.

In the SolidWorks session, we will be creating a mold for the outer cover of a disposable camera.  The steps we will follow are mentioned below:

 

  • Creating parting lines, shut-off surface, parting surface and mold blocks for the model.
  • Creating ejector pins for the mold.
  • Creating inserts for the mold.

 


6Gates and Runners / Mold Design Tutorial 3 - Part 1

 In the sixth week theory session we will be learning about runners and gates. The various topics covered are as follows:

  • Types of gates such as sprue, edge, tab, overlap, fan, disk, ring, spoke, film, pin, submarine and cashew gates.
  • Runner diameter calculation
  • Types of runners
  • Runner configurations
  • Why are engravings used in cavity



Then in the SolidWorks session we will be creating a mold for a door bezel model. Topics that will be covered are as follows:

 

  • Creating the parting lines, shut-off surfaces and parting surfaces of 3D profile for the model.
  • How to work in assemblies and how to arrange files in a specific format.
  • How to align the sprue of the mold with the origin of the assembly.
  • How to select proper dimensions for the mold blocks.
  • Creating mold blocks for door bezel.

 


7Mold Design Tutorial 3 - Part 2

In the seventh week, we will continue working on the door bezel model from the previous session and learn the following topics:

 

  • Locating undercuts in the model and understanding how the use of sliders will help in solving the undercut issue.
  • Creating slider split
  • How to assign proper dimensions to the slider
  • Editing the core cavity blocks according to the shape of the slider.
  • Creating bolts, washers and locking mechanism for the sliders.

 


8Mold Design Tutorial 4 - Part 1

In the eighth week, we will start creating a mold for a CPU fan case model and we will learn the following topics:

  • Complex parting line selection that can reduce the number of sliders required for the model.
  • How to provide correct matching drafts for the model.
  • Then we will create the core-cavity surfaces for the model. After that, we will align the sprue location, select dimensions and create the mold blocks for the CPU fan case in assembly. We will also see how to add reliefs for the core-cavity blocks.


9Mold Design Tutorial 4 - Part 2

In the ninth week, we will continue working on the CPU fan case model and we will learn the following topics:

 

  • Locating undercuts in the model 
  • Creating a slider split for the undercuts.
  • Assigning proper dimensions for the sliders.
  • Providing reliefs for the sliders.
  • Creating inserts for the model.

 

10Mold Design Tutorial 5 - Part 1

In the tenth week, we will start creating a mold for a plastic knob model and we will learn the following topics:

  • Creating the parting line, shut-off surface and the parting surfaces for the plastic knob model model. 
  • Automatic and manual shut-off surface creation.
  • Core-cavity surfaces for the plastic knob model.
  • Sprue alignment
  • Selecting dimensions and creating the mold blocks for the plastic knob in assembly. 

 

We will also be covering some theory behind the cooling channels for a mold.

 


11Mold Design tutorial 5 - Part 2

In the eleventh week, we will continue working on the plastic knob model and we will learn the following topics:  

 

  • Creating multiple inserts for the model
  • Creating holes for fixing the inserts. 
  • Locating undercuts and creating a slider split for it
  • Complex slider creation
  • Assigning proper dimensions for the slider.

 


12Mold Design Tutorial 5 - Part 3

In the twelfth week, we will continue working on the plastic knob model and we will learn the following topics:  

 

 

  • Creating an ejector system which will include the angled ejector pins, reliefs, ejector plates and ejector back plates.
  • How to make the channels for plastic injection which will include the sprue, runner and gate for the mold.
  • Understanding the use for providing air vents in a mold and then creating channels for the passage of air from the mold.
  • How to select the dimensions and positions of the cooling channels in the mold and how to create them

 



Projects Overview


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9 Months Access

$205.41

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  • Access Duration : 9 Months
  • Mode of Delivery : Online
  • Project Portfolio : Available
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  • Job Assistance : Lifetime
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  • Access Duration : Lifetime
  • Mode of Delivery : Online
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  • Individual Video Support : 24x7
  • Group Video Support : 24x7
  • Email Support : Available
  • Forum Support : Available
  • Telephone Support : Available
  • Add-ons Industry Projects : 15
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  • Paid Internship : 3 Months

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