Mechanical · PG program

Post Graduate Program inBIW Fixture and Plastic Design

The PG Program on automotive engineering trains you in important tools & technologies like CATIA V5, Siemens NX CAD and SOLIDWORKS. It is an ideal automotive design course for beginners.

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Duration: 24 weeks
Content: 82 hours
Courses: 5
Projects: 18
Mode: Online

Overview

What you'll
be able to do.

This course provides a basic understanding of the design and development processes of a vehicle body or shell.
Students will gain hands-on experience in using software that aid in the design and development of BIW fixtures/plastic components of a car.
This course provides knowledge on the engineering concepts behind the processes and how to solve challenges.

Why this program

Understanding of molding process, Gating, and Runner design ejecting methods, manufacturing feasibility check
You'll learn mechanical and electrical fundamentals including servicing, diagnostic, and repairs on things like the engine, steering, suspension, driveline, brakes, body control, and vehicle communication systems.

The student can get employed as
- BIW design engineer
- BIW fixture designer
- Mold simulation engineer
- Automotive plastics trims designer

Tools you'll use

CATIA V5Siemens NX CADSOLIDWORKS

Curriculum

5 courses,
48 modules.

Get the full syllabus ↓

01Automotive Plastic Design using CATIA V515 modules
1. Design Overview In Automotive IndustryW01
  - In this session, you will learn
    
    Product Life Cycle
    
    Design Life Cycle
2. Plastics in Automotive IndustryW02
  - In this session, you will learn
    
    Types of plastics (Thermoset Plastics, Thermoplastic)
    
    Engineering plastic Materials
    
    Manufacturing Process
    
    Injection Molding
3. Introduction to CATIAW03
  - In this session, you will learn
    
    Basic commands and operation
    
    Save feature, pan feature, rotate feature, etc
4. Sketcher workbenchW04
  - In this session, you will learn the following
    
    Commands
    
    Rules to follow
    
    Working in exercise
5. Part Design WorkbenchW05
  - In this session, you will learn
    
    Pad and pocket
    
    Working on exercise
6. Advanced part designW06
  - In this session, you will learn
    
    Boolean operations
    
    How to work on a Boolean exercise
    
    How to work on After Tool Go modification on Automotive components. (OEM Working procedures)
7. 2D Drawing creationW07
  - In this session, you will learn to
    
    Create a PCB Bracket using Boolean operations
8. Basic Surface Design WorkbenchW08
  - In this session, you will learn the following
    
    Commands (Types of Sweep)
    
    Working on exercise
    
    Draft analysis
    
    How to work on a surface exercise
9. Advanced Surface Design WorkbenchW09
  - In this session, you will learn the following
    
    Commands
    
    Creation of Closed body, Thickened body
    
    A parting line and parting surface
10. Creation of Door Switch Bezel and adding thickness to itW10
  - In this session, you will learn
    
    How to create tooling direction and do the draft analysis to ensure the part can be taken out of the tool?
    
    Adding the right thickness to the part and solving the issues.
    
    Create the parting line for the bezel.
11. Tooling FeasibilityW11
  - In this session, you will learn
    
    What is a mounting feature?
    
    How to create a locator and dog house?
    
    Integrating the mounting features to the base part with Boolean operations
12. Modeling ExerciseW12
  - In this session, you will learn
    
    The Clip mounting feature is in Plastic design.
    
    Design considerations for creating this feature
    
    Tooling analysis for the clip feature
13. Drafting WorkbenchW13
  - In this session, you will learn
    
    Drafting workbench
    
    Creation of detail drawing for the Components
    
    Views creations (basic view & section views)
    
    Application of GD&T in drawings
    
    Template settings
14. Mold Design ConsiderationsW14
  - In this session, you will learn
    
    Creation of Paring line
    
    Creation of Tooling axis
    
    What is undercut and how to solve it
15. Complex Mold Design ParametersW15
  - In this session, you will learn
    
    Creation of simple mold for the Rear quarter trim Cupholder
    
    What are core and cavity
    
    Stripper, ejection, and system
    
    Draft analysis
  - Designing a mold gives a good working understanding of the molding aspects of a component
02Automotive Sheet Metal Design using Siemens NX CAD / CATIA V56 modules
1. Vehicle development cycleW01
  - This is an introductory session where you will be introduced to the basics of automobiles along with different models of car bodies.
  - You will learn about the different stages of vehicle development that a car will go through before reaching the customer.
  - You will also learn about the three years of development activity that precedes the development of an automotive model.
2. Basics of Automotive Body in WhiteW02
  - In this session, you will be introduced to the basics of automotive BIW.
  - You will be introduced to the basics of steel and its properties in detail as steel is an important component used in the construction of automobiles.
  - The steps that are followed in the selection of the material will be discussed as well.
  - You will be given an introduction to cross-functional teams that exist 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.
3. Design Methodology of a Hood, Fender, Roof, Back Doors, and Side DoorsW03
  - In this module, we will focus 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
4. Case study - Converting - Backdoor/Tailgate Inner PanelW04
  - 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 will be shown.
  - Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:
    
    The 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
  - 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.
5. Design of key mechanism - Lock and StrikerW05
  - 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.
6. Case study Process and challenges with supplier manufactured partsW06
  - 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
03Automotive BIW Fixture Design using CATIA V510 modules
1. Introduction to BIW-FixtureW01
  - In this session, you will learn
    
    Definition of BIW, Jigs, & Fixture
    
    BIW-Nomenclature
    
    Types of Fixtures & their applications
    
    BIW stations & their uses
    
    Basic terminologies
2. BIW-Fixture BasicsW02
  - In this session, you will learn
    
    Project activities
    
    Different welding processes
    
    3-2-1 Principle
    
    Body planes
3. Pre-Design ProcessesW03
  - In this session, you will learn
    
    Design methodology
    
    Structuring a design tree
    
    Different types of fixture units
4. Units Design-1W04
  - In this session, you will learn
    
    Different types of Pin Unit Design
    
    Different types of Clamp Unit Design
    
    Different types of Rest Unit Design
5. Units Design-2W05
  - In this session, you will learn
    
    Dump Unit Design
    
    Slide Unit Design
    
    Base Unit Design
6. Finishing of the designW06
  - In this session, you will learn
    
    3D-finish
    
    Rough locators
    
    Pneumatic routing
    
    Valve banks & selection
    
    Gun study
    
    Sensors & selection
7. 2D-Detailing Basics W07
  - In this session, you will learn
    
    Drawing templates
    
    Angles of projection
    
    Basic GD&T used in fixturing
    
    Scaling & views
    
    Various detailing patterns
8. 2D-Detailing W08
  - In this session, you will learn
    
    Key Sheet detailing
    
    Unit detailing
    
    Child parts detailing
9. 2D-Detailing - Child Part & BOMW09
  - In this session, you will learn
    
    Child parts detailing
    
    Material selection
    
    BOM Preparation
10. Documentations, Sequence Sheet & Process SheetsW10
  - In this session, you will learn
    
    Creation of BOM sheets
    
    Creation of BOP sheets
04Advanced Sheet Metal Design using NXCAD5 modules
1. Introduction to NX CAD InterfaceW01
  - In this module, the student will learn how to create the sketches in NX CAD
    
    Students will also be performing functions such as,
    
    Creation of lines, circles, and squares
    
    Specifying the dimensions
    
    Pattern creation
2. Introduction to Sheet Metal Modelling InterfaceW02
  - In this module the students will be able to understand Tabs and Flanges
    
    Contour flange
    
    Advanced flange
    
    Jog flange
    
    Hem flange
    
    Corners, closed corners, and overlapping corners in sheet metal
    
    Adds a flange to an angle to a planar face and a bend between the two.
3. Conversion Wizards for Solid to Sheet MetalsW03
  - In this module, you will get a thorough understanding of:
    
    Edge rip
    
    Convert utility
    
    Cleanup utility
    
    Reliefs
    
    Face optimization
    
    Forming sheet metal from solid
4. Stiffening Features in Sheet MetalsW04
  - In this module, you will gain experience in:
    
    Beads creation
    
    Dimple creation
    
    Emboss creation
    
    Mirror features
    
    Feature patterns
5. Creation of Flattening and FormingW05
  - In this module, you will get an understanding of
    
    Neutral file data
    
    Surface extraction
    
    Adjacent and tangent face selections
    
    Flattening and thickening
05Mold Design using SOLIDWORKS12 modules
1. Basics of Injection Molding / SOLIDWORKS ModellingW01
  - In this week, the following topics are covered.
    
    Injection molding process
    
    Plastic processing methods
    
    Rotational molding
    
    Extrusion
    
    Vacuum forming
    
    Blow molding
    
    Gas-assisted injection molding
    
    Mold cycle and the factors affecting it
    
    Thermoplastics and thermosets
    
    Current trends in the industry
    
    Types of plastics
    
    Properties of plastics
    
    Selection of plastics
    
    Basics of sketching
    
    Basics of using features in SOLIDWORKS
2. Basics of Mold Design / SOLIDWORKS SurfacingW02
  - In this session, the following topics are covered.
    
    Product development process
    
    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
    
    Various surface tools for designing in SOLIDWORKS
3. DFM and DefectsW03
  - In this module, we will be covering theory related to various concepts and terms used in mold design.
  - The topics we shall cover are:
    
    Concept of machine tonnage and its calculation
    
    DFM study
    
    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.
    
    Defects in mold design process
    
    Short shots, flash, weld lines, sink marks, blisters, jetting, burn marks, warpage, gloss differences, hesitation, overpacking, and unbalanced flow.
4. Parting Surface / Mold Design Tutorial 1W04
  - In this module, we will be studying the theory behind parting surfaces.
  - The topics that will be covered are as follows:
    
    Parting surface
    
    Types of parting surfaces
    
    Flat stepped
    
    Angled
    
    Profiled
    
    Example cases to understand the selection of parting surfaces
    
    Matching drafts
    
    Shrinkage
    
    Inserts
    
    Mold design tutorial
    
    Doing draft analysis for the model
    
    Creating parting lines
    
    Creating shut-off surfaces
    
    Creating parting surfaces
    
    Create basic mold blocks
5. Sliders and Ejection System/ Mold Design Tutorial 2W05
  - In this module, 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
    
    General types of sliders
    
    Sliding split type molds
    
    Angular lift pin type molds
    
    Methods of actuating the sliders
    
    Finger cam
    
    Dog leg
    
    Cam track
    
    Spring
    
    Hydraulic actuation
    
    Concept of slider locking
    
    Types of ejector systems
    
    Pin
    
    Sleeve
    
    Stripper
    
    Blade ejector systems
    
    Creating a mold for the outer cover of a disposable camera
    
    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
6. Gates and Runners / Mold Design Tutorial 3 - Part 1W06
  - In this module, we will be learning about runners and gates.
  - The various topics covered are as follows:
    
    Types of gates: Sprue, edge, tab, overlap, fan, disk, ring, spoke, film, pin, submarines, and cashew gates
    
    Runner diameter calculation
    
    Types of runners
    
    Runner configurations
    
    Why engravings are used in cavities?
  - Creating a mold for a door bezel model
    
    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
7. Mold Design Tutorial 3 - Part 2W07
  - In this module, we will continue working on the door bezel model from the previous session and learn the following topics:
    
    Locating undercuts in the model
    
    Understanding the use of sliders in solving the undercut issue
    
    Creating slider split
    
    Assigning proper dimensions to the slider
    
    Editing the core cavity blocks according to the shape of the slider
    
    Creating bolts, washers, and locking mechanisms for the sliders
8. Mold Design Tutorial 4 - Part 1W08
  - In this module, we will start creating a mold for a CPU fan case model and we will learn the following topics:
    
    Complex parting line selection
    
    Providing correct matching drafts for the model
    
    Creating the core-cavity surfaces for the model.
    
    Aligning the sprue location
    
    Selecting dimensions
    
    Creating the mold blocks for the CPU fan case in the assembly
    
    Adding reliefs for the core-cavity blocks
9. Mold Design Tutorial 4 - Part 2W09
  - In this module, 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
10. Mold Design Tutorial 5 - Part 1W10
  - In this module, 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
    
    Theories behind the cooling channels for a mold
11. Mold Design Tutorial 5 - Part 2W11
  - In this module, 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
12. Mold Design Tutorial 5 - Part 3W12
  - In this module, we will continue working on the plastic knob model and we will learn the following topics:
    
    Creating an ejector system
    
    Angled ejector pins
    
    Reliefs
    
    Ejector plates
    
    Ejector backplates
    
    Making channels for plastic injection
    
    Sprue
    
    Runner
    
    Gate
    
    Use of air vents in a mold
    
    Creating channels for air passage
    
    Selection of the dimensions and positions of the cooling channels
    
    Creation of cooling channels

Industry projects

18 projects
you'll ship.

Our projects are designed by experts in the industry to reflect industry standards. By working through our projects, Learners will gain a practical understanding of what they will take on at a larger-scale in the industry. In total, there are 18 Projects that are available in this program.

Automotive BIW Fixture Design using CATIA V5

Designing a Robot Welding Fixture

In this project, the students will be working on the design and development of a robotic welding fixture. Here, the students will create the assembly and child-part drawings for th…

Automotive BIW Fixture Design using CATIA V5

Designing a Manual Welding Fixture

In this project, the students will be working on the design and development of a manual welding fixture. The students will also create the assembly and child-part drawings for the …

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Hood

In this particular project, you will be working on designing the inner panel of the hood, according to EURO NCAP standards.

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Fender Drip Area

In this particular project, you will be working on designing the Fender, according to EURO NCAP standards.

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Roof Assembly

In this particular project, you will design a complete roof assembly with all the necessary reinforcements using automotive standards.

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Tailgate

In this project, you will design and develop the complete Tailgate assembly using the given styling data.