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Master's Certification Program in Manufacturing Design

Master's Certification Program in Manufacturing Design

  • Pre-requisites : For Mechanical & Automotive Engineers
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A Quick Overview

Master's Certification program in Manufacturing Design 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. Wiring Harness using CATIA V5
    2. BIW fixture design using CATIA V5
      1. Automotive Sheet Metal Design using NX CAD
        1. Mold design using SolidWorks
        2. Geometric Dimensioning and Tolerancing using NX CAD
        3. Moldflow Analysis for Plastic Injection molding

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        Wiring Harness using CATIA V5 SYLLABUS

        1Basics of Vehicle Electrical Distribution System & Wiring Harness

         

        • Introduction to Vehicle Electrical Distribution System (EDS) 
        • Introduction to wiring harness assembly
        • Wiring harness design process for New Product Development (NPD)
        • Introduction to CATIA V5 electrical workbench

         


        2Introduction to CATIA V5 Electrical Workbench & Electrical Part Design

         

        • Customized settings for electrical environment
        • Wiring harness routing process for CATIA V5
        • CATIA V5 – electrical part design

         


        3Electrical Part Design

         

        • Clip/clamps/support part definition
        • Backshell definition
        • Protective covering definition

         


        4Harness Assembly & Installation – Part 1

         

        • Preparation of harness assembly
        • Creating the wire harness geometrical bundle
        • Inserting harness components into geometrical bundle
        • Positioning your inserted electrical parts
        • Connecting & disconnecting electrical components
        • Defining the wiring harness routing

         

         


        5Harness Assembly & Installation – Part 2

         

        • Wiring harness routing on external references 
        • Modifying the wire harness bundle segments
        • Wire harness protective coverings
        • Use of electrical splices
        • Bundle continuity check/analysis
        • Geometrical bundle warnings
        • 3D annotation

         


        6Harness Assembly & Installation – Part 3

         

        • Modifying the wire harness bundle segments
        • Modifying the branch point location
        • Deleting bundle segment
        • Bundle continuity check/analysis
        • Geometrical bundle warnings
        • 3D annotations
        • Important commands, tips, & techniques

         


        7Wiring Harness Flattening

        • Wiring harness flattening workbench

        • Flattening workbench settings

        • Flattening the 3D harness assembly

        • Modify flatten assembly

        • Saving the flatten Files

        • Drawing, creation & contents

        8Component Specifications & Selection Guide

        • Wiring harness component specifications & selection parameters
        • Available suppliers in market (India)

         


        9Wiring Harness Routing & Packaging Basics – Session 1

         

        • Definitions
        • Routing & packaging process
        • Design criteria (generic) for wiring harness 
        • Packaging rules & best practices
        • Guidelines for battery cables routing

         


        10Wiring Harness Routing & Packaging Basics – Session 2

         

        • Clearance management
        • Water ingress protection
        • Thermal protection management
        • Chaffing protection
        • Vibration protection
        • Routing on/near dynamic parts ( engine, wheel)
        • Harness bending rules (harness & battery cables)
        • Interconnection connector parking

         

         


        Projects Overview


        BIW fixture design using CATIA V5 SYLLABUS

        1Introduction to BIW-Fixture

        • Definition of BIW, jigs & fixture
        • BIW-nomenclature
        • Types of fixtures & their applications
        • BIW stations & their uses
        • Basic terminologies

        2 BIW-Fixture Basics

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

        3Pre-Design Processes

        • Design methodology
        • Structuring a design tree
        • Different types of fixture units

        4Units Design-1

        • Different types pin unit design
        • Different types of clamp unit design
        • Different types of rest unit design

        5Units Design-2

        • Dump unit design
        • Slide unit design
        • Base unit design

        6Finishing the design

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

        72D-Detailing Basics

        • Drawing templates
        • Angles of projection
        • Basic GD&T used in fixturing
        • Scaling & views
        • Various detailing patterns

        82D-Detailing 1

        • Key sheet detailing
        • Unit detailing
        • Child parts detailing

        92D-Detailing 2

        • Child parts detailing continued
        • Material selections
        • BOM preparation

        10Documentations

        • Design terminologies
        • Sequence sheets
        • Clamp validations sheets
        • Ergo-sheets
        • Poka-yoke
        • Fixture process sheet
        • Cycle time study


        Projects Overview


        Automotive Sheet Metal Design using NX CAD SYLLABUS

        1Vehicle Development Cycle

        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.

        2Basics of Automotive Body In White

        This will be an introductory session where the basics of the automotive BiW is taught. The basics of steel and its properties are covered, 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.

         


        3Design Methodology of a Hood, Fender, Roof and Side Doors

        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

         


        4Case study - Converting - RUECKWANDTUER INNER PANEL

        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.

         


        5Design of key Mechanism - Lock and Striker

        •  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.

         


        6Process and challenges with supplier manufactured parts

        • 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


        MOLD DESIGN USING SOLIDWORKS SYLLABUS

        1Basics of Injection Molding / SOLIDWORKS Modeling

          

        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. 
        • 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 backplates.
        • 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


        Geometric Dimensioning and Tolerancing using NX CAD SYLLABUS

        1Week 1: Introduction to GD&T

        In this module, you will study about GD&T and its uses. After your first class, you will be able to understand the basics such as:
        • Difference between traditional dimensioning and GD&T
        • Benefits of GD&T
        • How to read a feature control frame
        • Technical standards- ASME Y14.5M-2009
        • Different symbols used in GD&T, cover, and feature of size

        2Week 2: Rules, Symbols, and Form Tolerances

        In this module, you will learn about the governing rules of GD&T. After this class, you will have an understanding of:

        • Rule No. 1 (i.e. Taylor principle a.k.a envelope principle)
        • Rule No. 2 (regardless of feature size)
        • 14 symbols used in GD&T
        • Flatness, straightness, cylindricity, and circularity tolerances
        • MMC, LMC, and RFS conditions
        • Various examples for form tolerances

        3Week 3: Datums, Modifiers, Virtual Condition

        In this segment, you will study the following topics:

        • What are datums and how to apply datums to parts
        • Datum reference features
        • Datum feature modifiers
        • How to calculate virtual condition
        • Conjugated datums

        4Week 4: Orientation Tolerance and Profile Tolerance

        At the beginning of this section you will have built a good base for learning complex tolerances. In this section you will learn:

        • Profile of surface and profile of line
        • Perpendicularity tolerance, parallelism tolerance, and angularity tolerance
        • Composite profile tolerance
        • Various examples for orientation and profile tolerances

        5Week 5-6: Position Tolerance

        Position tolerance is the most widely used tolerance in GD&T.


        In this section we will go through:

        • Understanding true position
        • Projected tolerance
        • Composite tolerances
        • Tolerance zones- cylindrical, rectangular, spherical
        • Examples of position tolerance

        6Week 7: Co-axiality, Symmetricity, Run-outs

        By now, you will have enough knowledge to read an entire GD&T drawing and understand it. In this section, you will learn about some tolerances that are not widely used in industry but are mentioned in the ASME standard

        You will learn:

        • Coaxiality
        • Symmetricity
        • Circular and total run-outs
        • Examples

        7Week 8: Understanding GD&T Drawing

        In this part, you will study complex GD&T drawings and understand every individual tolerance and the message the tolerance conveys.





        Projects Overview


        Moldflow Analysis for Plastic Injection molding SYLLABUS

        1Operation of Moldflow/Inputs and Outputs of the Tool

        We deal with the 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

        • 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.

        • Creation 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 mesh. Creation of mesh and mesh correction tools are explained during this session.

        3Types 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.

        4Gate 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. 

        5Process Settings Guidelines

         

        • 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.

         


        6Result Analysis for Fill and Flow

         

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

         


        7Cooling 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. 

        8How 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.

        9Transient Cooling Analysis

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

        10Analysing the Results

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

        11Result Interpretations

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

         


        12Week-wise Consolidated Syllabus

        WEEK 1


        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.

        • Various methods of creating nodes.

        • Creation of lines and curves in different methods.

        • Creation of conformal cooling lines.

        • Creation of regions by using different options available.

        • Creation of local coordinate system.


        WEEK 2


        Designing a Marker pen model with the help of tools that was introduced in the previous week's challenge. After creating the geometry you will be taught how to generate a Dual domain mesh.

        • Setting up the geometry for meshing.

        • Checking and clearing the errors that can happen in the mesh.

        • Fixing the aspect ratio issues.

        • Checking the orientation of the mesh.

        • Checking the connectivity issues in the model.

        • Clearing the collapsed faces.

        • Overlap diagnostics.




        WEEK 3


        A) Generating a Midplane mesh out of a Dual domain mesh

        • Clearing the free edges present in the geometry.

        • Checking the thickness assigned to the midplane mesh that is generated.

        • Checking the orientation of the model.


        B) Generating 3D mesh in the geometry.

        • Advancing front mesher 

        • Advancing layer mesher

        • Tetra Advanced


        WEEK 4 


        Detecting the errors that can happen in a 3D mesh and its rectification 

        • Inverted Tetras

        Creating a ruler geometry and performing different types of meshes in it to show how mesh errors can be fixed in severe cases.


        WEEK 5


        In this module you will be introduced to initial analysis  which will help in determining the gate location, fill time and packing etc.

        • Gate Location Analysis

        • Molding Window Analysis

        • Fill Analysis

        • Fill+pack Analysis


        Creating a Gating system which includes

        • Creating the cold sprue

        • Creating the cold runner

        • Creating the cold gating system


        WEEK 6


        Learning how to select the suitable material for the analysis.

        Selection of the manufacturer and the trade name for the selected material.


        3 levels of material Quality Indicator

        • Fill Quality Indicator 

        • Pack Quality Indicator

        • Warp Quality Indicator


        Introduction to Process setting Wizard

        Setting up the values in the process setting wizard that is required to run the analysis.


        Setting up the ruler Geometry to run Fill+pack+warp Analysis


        Introduction to Optimization methods.

        • Parametric Study.

        • Design of experiments (DOE)


        WEEK 7


        • Explanation of the various results after running the Fill+pack+warp Analysis.

        • Results such as Fill time, Pressure at V/P Switchover, Volumetric shrinkage at ejection, Time to reach the ejection temperature, %shot weight XY plots, Air traps, Average velocity, Clamp tonnage, Weld lines, Meld lines, Deflection in all directions, Warpage

        • These results will be explained and if there are any defects then the remedies will also be explained.


        WEEK 8 


        For this week you will be equipped with how to create a COOLING CIRCUIT DESIGN for the ruler geometry which you created in the previous sessions.

        The cooling circuit plays the main role in maintaining the temperature inside the mold. 


        The weeks content covers topics such as:

        • Creating cooling circuits.

        • Creating Baffles and Bubblers

        • Selection of coolants

        • Cooling circuit Inserts


        You will also be creating a Glass tumbler geometry and creating the whole cooling circuit for the model including baffles and bubblers in it and making it ready to run the simulation.


        WEEK 9 


        • Here initially you will be setting up the case for the ruler geometry and running a cooling analysis on it.

        • Thereafter you will be setting up the case for the Glass Tumbler Geometry and making it ready to run the cooling analysis.

        • You will be introduced to the results obtained from the analysis.

        • Benefits of adding chiller circuits and how to set it up will be learned.






        WEEK 10


        In this module you will be introduced to Transient Cooling Analysis.This is an advanced type of cooling analysis where the molding tool is also analyzed. The setup for this analysis is explained. 

        • Setting up the case for Glass Tumbler geometry to run a Cool+Fill+Pack+Warp Analysis using FEM solver.

        • Setting up the case for Ruler geometry to run a Cool+Fill+Pack+Warp Analysis using BEM Solver.

        • Setting up a  Mold Block for Cooling Analysis.

        • Beryllium-Copper Inserts. 


        WEEK 11


        Analyzing the results using different solvers in different models.The result obtained with different types of analysis is discussed here. The result interpretation and the basic solutions are also explained.

        • Cooling Analysis results using BEM Solver

        • Cooling Analysis results using FEM Solver


        WEEK 12

        Result interpretations and Report Generation after obtaining the results

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

        • How to generate a proper report in order to substantiate the results that you obtained with the help of Moldflow.


        Projects Overview


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