Gap and Flushness in Automotive Body Design using CATIA V5

Gap and Flushness in Automotive Body Design

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A Quick Overview

Hundreds of components contribute to creating a finished product, especially in the automotive and aerospace industries. Each component may be manufactured by different suppliers, in different locations, using many wide and varied processes that eventually all have to fit together to make one final product. This means that fit and quality control is vital, gap and flush measurements are highly beneficial. If fit and finish are out of specification, it affects not only the aesthetics of the product but also the performance, efficiency and increases the risk of failure.
Aesthetic quality has no precise definition since it is a qualitative product attribute that is perceived by a customer through visual inspection and comparison. Variation of features such as the size and shape of gaps and the flushness between mating components are areas that need to be tightly controlled during design and manufacture to maintain the aesthetic quality of a product. The ability to predict and assess how manufacturing variation will affect the aesthetic quality of a product early in the design process results in fewer design changes due to unanticipated problems later in the product's life cycle.


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Gap and Flushness in Automotive Body Design using CATIA V5

Download Syllabus


1Fundamental Aspects

  • Product design procedure
  • Section book
  • Why do we set Gaps and Flushness
  • Understand and interpreting engineering drawings
  • General tolerances

2Geometric Tolerance

  • What is Geometric Tolerancing
  • Introduction to symbols and their meanings
  • Introduction to feature frame
  • Developing a Datum
  • Creating a Datum

3Most Usable Tolerances in Sheetmetal Design

  • Form tolerance
  • Profile tolerance
  • Location tolerances
  • Material condition

4Vehicle Components Tolerances

  • Overview of a vehicle's exterior parts
  • Common tolerancing of vehicle parts
  • Understanding the common tolerance values of different areas

5Master Controls

  • Master control points
  • Master control surfaces
  • Matching surfaces
  • Translating references onto a drawing. 

6Processing Tolerance

  • Learning the purpose of making out processing Tolerance
  • Scope to adopt processing tolerance 
  • The definition of terminology 
  • What is the condition to decide processing tolerance 
  • The method to calculate tolerance 
  • The standard to establish processing tolerance 

7Processing Tolerance Examples

  • Hood / Fender
  • Fender / Front door
  • Front Pillar / Door frame
  • Front Door / Rear door
  • Door / Side frame
  • Design targets and benchmarking

8Stack Up Analysis

  • Tolerance analysis techniques
  • Basic tolerance for stack up 
  • Tolerance analysis for each case
  • HSG lamp stack up

9Stack Up Analysis of Pillars

  • A-Pillar stack up analysis
  • B-Pillar stack up analysis

10Stack Up Analysis of Side Body Exterior

  • Summary result
  • Stack-up analysis on side panel out steps

11Assembly Drawing

  • Illustration of stack up on drawing
  • Provide an assembly drawing
  • Show the stack up on drawing


  • Providing Gap and Flushness drawing
  • Procedure to amend the errors
  • The most reputable software and how it works


  • Students in Mechanical, Aerospace or Automotive engineering
  • Freshers looking to gain project experience on CATIA


Flexible Course Fees

Choose the plan that’s right for you


2 Months Access


Per month for 3 months

  • Access Duration : 2 months
  • Mode of Delivery : Online
  • Project Portfolio : Available
  • Certification : Available
  • Email Support : Available
  • Forum Support : Available

Lifetime Access


Per month for 3 months

  • Access Duration : Lifetime
  • Mode of Delivery : Online
  • Project Portfolio : Available
  • Certification : Available
  • Individual Video Support : 12/month
  • Group Video Support : 12/month
  • Email Support : Available
  • Forum Support : Available
  • Telephone Support : Available
  • Dedicated Support Engineer : Available


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  • Top 5% of the class will get a merit certificate
  • Course completion certificates will be provided to all students
  • Build a professional portfolio
  • Automatically link your technical projects
  • E-verified profile that can be shared on LinkedIn


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Frequently Asked Questions

1Who can take your course?

Graduate and Post Graduate Mechanical and Automotive engineering students from final year and freshers. Anyone at the beginning stage of vehicle (product) design engineering.

2What is included in your course?

Overview of Geometric Dimensioning and Tolerancing, Auxiliary Drafting and Drawing for Assemblies, Stack Up Analysis

3What will the student gain from your course?

The concept of Gap and Flushness and how to define them, Stack Up Analysis to calculate Gaps and Flushness's to achieve the targets of design 

4What software skills are you teaching and how well are these tools used in the industry?

The course is basically theoretical in which CATIA V5 is to obtain parts and assemblies’ drawing as an essential part of any engineering design operation.

5What real world application for the tools and techniques will you teach in this course?

Automotive, Railways, Home Appliance, Electrical Devices and Medical Machines 

6Which companies use these techniques and for what?

Almost all industrial companies are using such methods such as BMW, Airbus, Toyota, Sony, Nissan, Philips, Volkswagen, LG, Samsung, Dailmer, Valeo etc.

7How is your course going to help me in my path to MS or PhD?

You will learn about basic fundamentals & analytical skills which are desirable for higher education

8How is this course going to help me get a job?

This course provides a bigger perspective of Mechanical Design Engineering and / or you may apply this knowledge for your project activities also. These efforts can help you to get an interview call from myriads of different reputable industrial companies.

9What is the ratio of theory to hands-on practical content?

In this course, the ratio is almost 50 / 50, however, the quality and impact of pragmatic content is more.

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