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Master's Certification in Complete Passenger Car Design & Product Development

Domain : Product Development, Design

Pre-requisites : For Mechanical & Automotive Engineers

Introduction

A Quick Overview

Masters Certification program in Complete Passenger Car Design & Product Development is a 6 month long, intensive program. The program comprises of 6 courses that train you on all the essential engineering concepts and tools that are essential to get into top OEMs.

Courses included:

    1. Automotive Class A surfacing using ALIAS
    2. Surface Modelling of an Aston Martin Car using SolidWorks
    3. Automotive Sheet Metal Design using NX CAD
    4. Automotive Lighting Design CATIA V5
    5. Automotive Plastic Design using CATIA V5
    6. Automotive Seating Design using Catia V5

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    Course One: Automotive Class A surfacing using ALIAS

    • Introduction to Alias
    • What is design? About CAID/CAD design
    • User interface and navigation tools
    • Basic object selection and viewing
    • Importing sketches as images or canvases
    • Working with layers
    • Introduction to curve tools. Basics, U’s & V’s, spans.
    • Create symmetrical curves
    • Transform curves, creating curve fillets, curve sections and offset curves
    • Controlling geometry, mirroring, grouping, duplicating objects 
    • Object lister, CV sculpting, concept sculpting
    • Surface toolbar, edit and shade
    • Difference between surfaces and solids
    • Surfaces from boundaries, bezier surfaces, 
    • Nurbs & slab modeling
    • What are parent surfaces? Primary surfaces, secondary surfaces
    • Sharp surface models
    • Primary fillets, blends, secondary fillets, blends
    • Chord fillet & radius fillet
    • Trimming, creating curves on surfaces
    • Trimming surfaces, intersect surfaces, filleting surfaces
    • Adding variable radius fillets
    • G0 - positional
    • G1 - tangent
    • G2 - curvature
    • G3 - curvature
    • Introduction to concept modeling 
    • Construction options Introduction 
    • Dimensions 
    • Overlay canvasses for design and presentation. 
    • Building with curves & surface tools 
    • Modeling approaches and surface distribution 
    • Working accurately
    • Overlay canvass for design
    • Surface understanding by three-quarter views.
    • Building with curves & surface patching 
    • Modeling approaches and surface distribution
    • Understanding of component design 
    • Hypothetical surfaces to create patch layout 
    • Work more on the creative side: Imagine the surfaces
    • Understanding of component design 
    • Hypothetical surfaces to create patch layout 
    • Work more on the creative side: Imagine the surfaces
    • Understanding surfaces, patches, layout 
    • Idea of how to divide surfaces 
    • Building techniques, where to start 
    • Make your way up to the top 
    • Parent patches - foundation
    • Introduction to technical surfacing
    • Surface evaluation - reflection lines
    • Surface evaluation - cross-sections & comb plots
    • Construction tolerances between surface patches
    • Transform CV - fine-tuning control points
    • Working with trimmed edges - fit curve & align project
    • Fulfilling every parameter 
    • A well thought patch construction 
    • Patches with proper cv’s layout 
    • Proper passing of positional, tangent and curvature surfaces 
    • Proper evaluated surfaces 
    • Making way up to Class-A Model
    • Introduction to reverse engineering 
    • Working with mesh data 
    • Working with sections 
    • Creating a surface onto a mesh 
    • Analyzing and displaying deviation 
    • Reference manager for handling large data sets
    • Rendering in Alias 
    • Hardware rendering, shades, lighting, environments 
    • Creating image files

    Projects Overview

    Modeling Project

    Model the car of the given blueprint and prepare the CAS volume surface with the terminologies covered. Make sure the design element isn’t suffered while building clean curves & Surfaces. The Process of creating, first- A patch curve network then surface building shall be applied in modeling. Create a curve network as required. Once volume has completed the process of filleting should be applied to the entire model.

    Presentation Design Project

    Complete the detailed car model and the industry techniques we have studied in this course must be applied for rendering and image creation. Apply different materials a visualize the best one. Complete other models as well and have it rendered while preparing a presentation of all the 3D models.

    Course Two: Surface Modelling of an Aston Martin Car using SOLIDWORKS

    • Sketching tools
    • Surface modeling tools
    • Types of tools to create the surfaces
    • Blueprint setups 
    • Splines
    • Spline vectors
    • Equal curvature for splines
    • Constraining the splines
    • Projected curve creation
    • Composite curve generation
    • Types of surfaces
    • Boundary surfaces
    • Lofted surfaces
    • Filled surfaces
    • Ruled surfaces
    • Reference planes
    • Surface trims
    • Surface knit
    • Move/copy surfaces
    • Mirror surfaces
    • Revolve boss
    • Extrude cut
    • Linear and circular patterns
    • Fillets
    • Chamfers
    • Split bodies
    • Creation of wheels
    • Inserting the parts
    • Mates in assembly
    • Sub-assembly creations
    • Difference between float and fix parts
    • Importing sub-assemblies to other assemblies
    • Application of decals
    • Appearances adjustment

    Projects Overview

    Surface Modeling of Aston Martin One - 77

    In this project, you will be able to build an entire Aston Martin car using SOLIDWORKS.

    • Modeling and Assembly of Aston Martin car 
    • Blueprint setup
    • Modeling of roof, sides, back rails
    • Modeling of windshields, windows, rear lights and front lights
    • Modeling of rims, wheels, disc brake calipers  
    • Creation of emblem
    • Creation of wheel sub-assembly.
    • Modeling back reflectors
    • Final assembly model of Aston Martin One-77 car


    Course Three: Automotive Sheet Metal Design using NX CAD

    This will be an introductory session where the basics of the automobiles and types of car bodies are explained. The complete vehicle development process which will explain the stages crossed by a car before it reaches the customer. The complete 3 years of development activity will be explained.

    This will be an introductory session where the basics of the automotive BiW is taught. The basics of steel and its properties are covered in detail, as steel is an important component used in the cars. Steps followed in the selection of the material is discussed. Also, the cross-functional teams are explained and the need to coordinate with them is explained with the master sections and 3D components of the parts for easy and clear understanding.




    Out of all the BiW components, we will focus our attention on the hood, fender, roof, side, 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



    In this, we will present a real-life scenario where the effect of converting an inner panel from aluminum cast to the steel deep draw part will be presented. 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 aluminum liftgate

    • Tailgate outer parting was maintained 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.



    • In this module, you will first learn 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 tiniest components. In this module, we will be analyzing the locker and striker mechanism in detail.



    • 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

    Projects Overview

    Hood Design

      • In this particular project, you will be working on designing the inner panel of a hood, according to euro cap standards and make sure that the part is the manufacturer.

      • You will provide all the necessary reinforcements at the necessary regions and join the outer and inner panel using the proper joining methods.

      • You will also make sure that all the manufacturing requirements are being satisfied with all the cad parts that you design.



      Fender Drip Area Design

        • In this particular project, you will be working on designing the drip area for the given fender, where you will make sure to follow certain dimensions that are required to be followed for the drip area.

        • In addition to that, you will also provide the necessary bead and other emboss to strengthen the component.

        • you will make sure that the output part meets all the tolerances to be satisfied for the deep drawing process.



        Roof Design

          • In this particular challenge, you will develop the ditch area and roof reinforcements.

          • You will also be doing calculations to see if the roof passes the snow load criteria and heat distortion criteria.

          • The number of bow roof rails will also be calculated from the above calculation.



          Tailgate Design

          • In this project, you will develop the inner panel of a tailgate by suggesting a tooling direction. And also make sure that the inner panel clears the draft analysis

          • You will also develop all the necessary reinforcements for the tailgate design like Hinge and Latch reinforcements and gas stay reinforcements etc. 

          • In addition to this, you will also develop the outer panel for the tailgate from the given skin data



          Course Four: Automotive Lighting Design CATIA v5

          • Some old school phenomena of physics-related to lighting
          • How basic physics use into real-time application
          • Basic name and application of automobile lighting Ex – Headlight, tail light etc. 
          • The function of light, example  - Turn indication, high beam, low beam
          • CATIA basic model, workbench, some basic command  (in CATIA)
          • Some practice session on basics features, Like, boss, Locators (in CATIA)


          • Information about regulations and its function
          • Start making lamp (Class A analysis) (in CATIA)
          • B surface creation (all into separate parts in CATIA) 
          • Feature implementation (in CATIA)
          • More deep information for regulation and how to check into 3D
          • Draft analysis, basic check for model(in CATIA)

          • Basic Plastic, understanding while designing parts (in CATIA)
          • Making joining section (Glue, hot plate, vibration, etc)
          • Making all in single files (in CATIA)
          • Publish command in CATIA and join all parts together
          • Making mounting concept with 3,2,1 principle surrounding check (in CATIA)
          • C regulation into 3D (in CATIA


          • Checking all data as per tooling requirement( only basic) in CATIA
          • Start making a 2D drawing from 3D ((in CATIA)
          • Tolerance, Dimension (in CATIA)
          • Complete revision (basic only)
          • Making small lamp again as per regulation, plastic and tooling requirement
          • Understanding industry requirements, optics, thermal, RFQ and other key elements to getting into this domain  


          Projects Overview

          3D Drawing

          Create compete 3D following a given section. Every area section should be the same, without changing given surfaces


          Tail Lamp Design

          Create a complete tail lamp using a hot plate welding section
          Lens rib height - minimum 8-10 mm
          Interference - 1.5 mm
          The thickness of lens - 2.5 mm
          Housing thickness - 2 mm
          Reflector thickness - 2 mm
          Boss - m4x10 screw
          Positive mounting for the lamp  - m5 screw
          Wiring harness create
          Wire routing create
          Clip mounting and stud mounting features


          Course Five: Automotive Plastic Design using CATIA v5

          • Product life cycle
          • Design life cycle
          • Types of plastics (thermoset plastics, thermoplastic)
          • Engineering plastic materials
          • Manufacturing process
          • Injection molding
          • Basic commands and operation.
          • Save, pan, rotate etc.
          • Commands, 
          • Rules to follow
          • Working in exercise
          • Pad, pocket
          • Working on exercise
          • Boolean operations
          • Working on Boolean exercise
          • Working on after tool go modification on automotive components. (OEM working procedures)

          Create a PCB bracket using Boolean operations

          • Commands (t0ypes of sweep)
          • Working on exercise
          • Draft analysis
          • Working on surface exercise
          • Commands 
          • Creation of closed body, thickened body
          • Parting line, parting surface
          • How to create tooling direction and do the draft analysis to ensure the part can be taken out of tool?
          • Adding right thickness to the part and solve the issues
          • Create the parting line for the bezel
          • In this section we will learn on what is a mounting feature
          • How to create a locator and dog house?
          • Integrating the mounting features to the base part with Boolean operations
          • We will learn what is the Clip mounting feature is in Plastic design.
          • Design considerations for creating this feature
          • Tooling analysis for the clip feature
          • Drafting work bench.
          • Creation of detail drawing for the Components
          • Views creations (basic view & section views)
          • Application of GD&T in drawings
          • Template settings
          • Creation of Paring line
          • Creation of Tooling axis
          • What is undercut and how to solve it
          • Creation of simple mold for the Rear quarter trim Cup holder
          • What is core and cavity
          • Stripper, ejection and system
          • Draft analysis

          Designing a mold gives a good working understanding in the molding aspects of a component

          • Instrument panel bezel with undercut
          • Creation of mold with side core, and lifter
          • Clear picture of undercut and other tooling complications
          • Draft analysis for complex part
          • Plastic defects faced in automotive design
          • Real-time examples and solution for these designs
          • Component out of Complex Class A surface
          • Solving Class-A before starting Design (OEM Procedure)
          • Complex surfaces that cannot be thickened easily
          • Draft analysis to check the part for tooling.
          • OEM Standard output presentation

          Assemble Automotive Sub-assemblies including Child part, Screws,  

          How to create Assemblies in CATIA?

          Creating Constraints

          Assembly sectioning analysis

          Proximity analysis and output preparation.

          Compare analysis of 2 similar components OEM Working procedure

          • Develop door trim from surfaces, and Master section
          • Develop Fixation and feature from door trim
          • Develop switch bezel from studying master section.  
          • Gap and Flush analysis
          • OEM Standard output presentation

          Projects Overview

          Development of a Door Trim panel for Segment Car

          • Creation of CAD model considering following inputs as like in OEM and tier1 companies
          • Class A surface
          • Nominal thickness
          • Attachment strategy
          • Environment feasibility
          • Create the mounting features as per design guidelines in the industry
          • Apply required colour and material details
          • Draft analysis & Tooling analysis
          • Creation of parting lines and check tooling feasibility

          Development of Rear Lamp with a given Master Section

          • GCreation of CAD model considering following inputs as like in OEM and tier1 companies
          • Master section will be given as input 
          • CAD has to create considering the section and class A as Inputs.
          • Body side fixation, its design rules
          • Nominal Thickness addition with thickness as parameter with close surface option
          • Definition of mounting strategy and creation of mounting features considering       3-2-1 pin location (with locators, clip mounting, dog houses and Screws)
          • Apply required colour and material details
          • Draft analysis 

          Creation of Master Section

          • Inputs of class A and 2 environments past will be given
          • Master section should be developed to show 
          • Part thickens
          • Fixation strategy
          • Assembly strategy

          Course Six: Automotive Seating Design using CATIA v5

          In this section, we will have a brief on Introduction of Automotive Structure, Seats & its Nomenclature.

          In this section, we will have a brief on types of Seats, how the seats are defined as per the number of rows in the Car and Number of Movement in the seat.
          This section contains information about the parts/component used to design/develop a seat as per the requirement from the customer. It will also have a basic mechanism used in a seat to provide the movements. It is defined in two segments: 
          • Front Row Components 
          • Rear Row Components
          In this section, we will brief about the components - Foam. Following points will be covered during the course with hands-on CATIA model.

          • How many types of Foam are available
          • Design Standard for Foam
          • Methods of foam development/Manufacture
          • Defects in Foam

          In this section, we will brief about the components – Structure. Following points will be covered during the course with hands on Catia model.
          • Types of Structure
          • Component of Structure
          • Design guideline
          • The material used in manufacturing
          • Methods used to develop structure

          In this section, you will learn the following.

          • Types of Headrest used in automotive seats.
          • Components used in making headrest
          • Use of Headrest

          In this section, you will learn the following.

            • Types of Trims used in Automotive
            • The terminology used in Trims
            • Defects during the development of trim
            • Methods to assemble trims

            Following points will be covered during the section:


            • Types of Plastic ( Material/Usage differentiation)
            • Nomenclature of plastic parts in the seat
            • Efficient ways to use plastic in a seat
            • Defects occur on plastic components

            In this section, you will learn the following.  

            • Types of Armrest
            • Mechanism of Armrest
            • Components of an Armrest
            • Manufacturing Defects of Armrest

            In this course we will brief about details of all the mechanism used in Automotive passenger seats including types of Mechanism used and nomenclature:


            • Recliner – Work/Function and detail study
            • Track – Work/Function and detail study
            • Height Adjuster – Work/Function and detail study

            In this course will provide a glimpse of testing of seat at Car/Seat level which will include below:

            • Safety related Test
            • Regulatory related Test
            In this course will provide a glimpse of testing of a seat at Car/Seat level which will include below :

            • Comfort mechanism
            • New Innovation Idea
            • Comfort layouts of Seats

            This section of the course will not be only generalized to seating but this method can be used all over the globe in any domain to solve a problem:


            • 8D
            • Fish Bone Diagram
            • 5D
            • Man-Machine Diagram

            This section of the course will not be only generalized to seating but this method can be used all over the globe in any design-related program :

            • What are DFMEA and PFMEA
            • The process to prepare DFMEA and PFMEA
            • Different Review points of DFMEA and PFMEA

            This section of the course will not be only generalize to seating but this methods can be used all over globe in any design related program :

            • Introduction to GD&T
            • Usage of GD&T in seats
            • Different examples to define GD & T with exercise to do

            This section of the course will not be only generalized to seating but this method can be used all over the globe in any program :

            • Life Cycle of a program
            • Different stages a program goes
            • Mile Stones of Customers

            Flexible Course Fees

            Choose the Master’s plan that’s right for you

            Basic

            6 Months Access

            $270.99

            per month for 6 months

            Access Duration : 6 Months Duration for which your course videos, challenges and projects will be made available from the time of enrollment.

            Mode of Delivery : Online Lessons are administered by expert instructors with pre-recorded videos of lesson plans.

            Project Portfolio : Available An exclusive project portfolio page to showcase your various projects and certifications that can be linked to your online resume and job profiles.

            Certification : Available Course completion & merit (top 5%) certificates that can be linked to your online profile to build your professional portfolio.

            Individual Video Support : 8/Month One-on-One zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Group Video Support : 8/Month Group zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Email Support : Available Queries & doubts answered via email by our technical support engineers.

            Whatsapp Support : Available Access to course-specific Whatsapp Group to connect with peers and have queries & doubts answered by our technical support engineers.

            Pro

            12 Months Access

            $406.49

            per month for 6 months

            Job Assistance : Available Expert guidance in resume building, mock interviews & tool tests and connecting with recruiters and organizations for interviews.

            Master's Assistance : Available Expert guidance in Scholarship/MS applications, crafting statement of purpose, project submissions and more.

            Access Duration : 1 year Duration for which your course videos, challenges and projects will be made available from the time of enrollment.

            Mode of Delivery : Online Lessons are administered by expert instructors with pre-recorded videos of lesson plans.

            Project Portfolio : Available An exclusive project portfolio page to showcase your various projects and certifications that can be linked to your online resume and job profiles.

            Certification : Available Course completion & merit (top 5%) certificates that can be linked to your online profile to build your professional portfolio.

            Individual Video Support : 16/Month One-on-One zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Group Video Support : 16/Month Group zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Email Support : Available Queries & doubts answered via email by our technical support engineers.

            Whatsapp Support : Available Access to course-specific Whatsapp Group to connect with peers and have queries & doubts answered by our technical support engineers.

            Telephone Support : Available Queries & doubts answered via telephone by our technical support engineers.

            Add-ons Industry Projects : 10 Industry-oriented projects to help you upskill and bolster your resume

            Premium

            Lifetime Access

            $541.99

            per month for 6 months

            Job Assistance : Lifetime Expert guidance in resume building, mock interviews & tool tests and connecting with recruiters and organizations for interviews.

            Master's Assistance : Lifetime Expert guidance in Scholarship/MS applications, crafting statement of purpose, project submissions and more.

            Access Duration : Lifetime Duration for which your course videos, challenges and projects will be made available from the time of enrollment.

            Mode of Delivery : Online Lessons are administered by expert instructors with pre-recorded videos of lesson plans.

            Project Portfolio : Available An exclusive project portfolio page to showcase your various projects and certifications that can be linked to your online resume and job profiles.

            Certification : Available Course completion & merit (top 5%) certificates that can be linked to your online profile to build your professional portfolio.

            Individual Video Support : 24x7 One-on-One zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Group Video Support : 24x7 Group zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Email Support : Available Queries & doubts answered via email by our technical support engineers.

            Whatsapp Support : Available Access to course-specific Whatsapp Group to connect with peers and have queries & doubts answered by our technical support engineers.

            Telephone Support : Available Queries & doubts answered via telephone by our technical support engineers.

            Add-ons Industry Projects : 15 Industry-oriented projects to help you upskill and bolster your resume

            Offline Skill-Center Access : Available Complete access to instructor interactions and live workshops at our state-of-the-art Skill-Centers

            Dedicated Support Engineer : Available Personalized and exclusive hands-on support from an expert engineer assigned to answer your queries & doubts and support your course progress.

            Paid Internship : 3 Months 3-month Paid Internship with the scope to work on exclusive industry-oriented projects

            Basic

            6 Months Access

            $270.99

            per month for 6 months

            Access Duration : 6 Months Duration for which your course videos, challenges and projects will be made available from the time of enrollment.

            Mode of Delivery : Online Lessons are administered by expert instructors with pre-recorded videos of lesson plans.

            Project Portfolio : Available An exclusive project portfolio page to showcase your various projects and certifications that can be linked to your online resume and job profiles.

            Certification : Available Course completion & merit (top 5%) certificates that can be linked to your online profile to build your professional portfolio.

            Individual Video Support : 8/Month One-on-One zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Group Video Support : 8/Month Group zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Email Support : Available Queries & doubts answered via email by our technical support engineers.

            Whatsapp Support : Available Access to course-specific Whatsapp Group to connect with peers and have queries & doubts answered by our technical support engineers.

            Pro

            12 Months Access

            $406.49

            per month for 6 months

            Job Assistance : Available Expert guidance in resume building, mock interviews & tool tests and connecting with recruiters and organizations for interviews.

            Master's Assistance : Available Expert guidance in Scholarship/MS applications, crafting statement of purpose, project submissions and more.

            Access Duration : 1 year Duration for which your course videos, challenges and projects will be made available from the time of enrollment.

            Mode of Delivery : Online Lessons are administered by expert instructors with pre-recorded videos of lesson plans.

            Project Portfolio : Available An exclusive project portfolio page to showcase your various projects and certifications that can be linked to your online resume and job profiles.

            Certification : Available Course completion & merit (top 5%) certificates that can be linked to your online profile to build your professional portfolio.

            Individual Video Support : 16/Month One-on-One zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Group Video Support : 16/Month Group zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Email Support : Available Queries & doubts answered via email by our technical support engineers.

            Whatsapp Support : Available Access to course-specific Whatsapp Group to connect with peers and have queries & doubts answered by our technical support engineers.

            Telephone Support : Available Queries & doubts answered via telephone by our technical support engineers.

            Add-ons Industry Projects : 10 Industry-oriented projects to help you upskill and bolster your resume

            Premium

            Lifetime Access

            $541.99

            per month for 6 months

            Job Assistance : Lifetime Expert guidance in resume building, mock interviews & tool tests and connecting with recruiters and organizations for interviews.

            Master's Assistance : Lifetime Expert guidance in Scholarship/MS applications, crafting statement of purpose, project submissions and more.

            Access Duration : Lifetime Duration for which your course videos, challenges and projects will be made available from the time of enrollment.

            Mode of Delivery : Online Lessons are administered by expert instructors with pre-recorded videos of lesson plans.

            Project Portfolio : Available An exclusive project portfolio page to showcase your various projects and certifications that can be linked to your online resume and job profiles.

            Certification : Available Course completion & merit (top 5%) certificates that can be linked to your online profile to build your professional portfolio.

            Individual Video Support : 24x7 One-on-One zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Group Video Support : 24x7 Group zoom support sessions to discuss study plan, progress and to have your queries & doubts answered.

            Email Support : Available Queries & doubts answered via email by our technical support engineers.

            Whatsapp Support : Available Access to course-specific Whatsapp Group to connect with peers and have queries & doubts answered by our technical support engineers.

            Telephone Support : Available Queries & doubts answered via telephone by our technical support engineers.

            Add-ons Industry Projects : 15 Industry-oriented projects to help you upskill and bolster your resume

            Offline Skill-Center Access : Available Complete access to instructor interactions and live workshops at our state-of-the-art Skill-Centers

            Dedicated Support Engineer : Available Personalized and exclusive hands-on support from an expert engineer assigned to answer your queries & doubts and support your course progress.

            Paid Internship : 3 Months 3-month Paid Internship with the scope to work on exclusive industry-oriented projects

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