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

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

  • Pre-requisites : For Mechanical & Automotive Engineers
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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. Automotive Sheet Metal Design using NX CAD
  3. Automotive Plastic Design using CATIA V5
  4. Automotive Wiring Harness using CATIA V5
  5. Automotive Lighting Design CATIA V5
  6. Automotive Seating Design using Catia V5


Get a 1-on-1 demo to understand what is included in the course and how it can benefit you from an experienced sales consultant. The demo session will help you enroll in this course with a clear vision and confidence.

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Download Syllabus

Course One: Automotive Class A surfacing using ALIAS

1Digital Design Foundation 1 & Curves Introduction, Why use Curves

  • 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

2Digital Design Foundation 2 & Building and Controlling Simple Geometry

  • Controlling geometry, mirroring, grouping, duplicating objects 
  • Object lister, CV sculpting, concept sculpting

3Digital Design Foundation 3, Surface Editing & Introduction to Different Continuities

  • 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

4Surface Editing

  • Trimming, creating curves on surfaces
  • Trimming surfaces, intersect surfaces, filleting surfaces
  • Adding variable radius fillets

5Introduction to Different Continuities

  • G0 - positional
  • G1 - tangent
  • G2 - curvature
  • G3 - curvature

6Workflow 1: Concept Modeling

  • 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

7Workflow 2: Concept Modeling

  • Overlay canvass for design
  • Surface understanding by three-quarter views.
  • Building with curves & surface patching 
  • Modeling approaches and surface distribution

8Workflow 3: Concept Modeling

  • Understanding of component design 
  • Hypothetical surfaces to create patch layout 
  • Work more on the creative side: Imagine the surfaces

9 Workflow 4: Concept Modeling

  • Understanding of component design 
  • Hypothetical surfaces to create patch layout 
  • Work more on the creative side: Imagine the surfaces

10Workflow 5: Concept Modeling

  • 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

11Technical Surfacing (A- Class Knowledge)

  • 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

12Class B Surfaces Modeling

  • 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

13Reverse Engineering

  • 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

14Presenting Your Design

  • Rendering in Alias 
  • Hardware rendering, shades, lighting, environments 
  • Creating image files

Projects Overview

Course Two: Automotive Sheet Metal Design using NX CAD

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 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.


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

Course Three: Automotive Wiring Harness Design using CATIA V5

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

Course Four: Automotive Plastic Design using CATIA v5

1Design Overview In Automotive Industry

  • Product life cycle
  • Design life cycle

2Plastics in Automotive Industry

  • Types of plastics (thermoset plastics, thermoplastic)
  • Engineering plastic materials
  • Manufacturing process
  • Injection molding

3Introduction to CATIA

  • Basic commands and operation.
  • Save, pan, rotate etc.

4Sketcher Workbench

  • Commands, 
  • Rules to follow
  • Working in exercise

5Part Design Work Bench

  • Pad, pocket
  • Working on exercise

6Advanced Part Design

  • Boolean operations
  • Working on Boolean exercise
  • Working on after tool go modification on automotive components. (OEM working procedures)

7Creation of PCB Bracket using Boolean Operations

Create a PCB bracket using Boolean operations

8Surface Design Work Bench

  • Commands (t0ypes of sweep)
  • Working on exercise
  • Draft analysis
  • Working on surface exercise

9Advanced Surface Design Work Bench

  • Commands 
  • Creation of closed body, thickened body
  • Parting line, parting surface

10Creation of Trim Bezel and Adding Thickness to it

  • 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

11Creation of the Positioning and Fixation Features for Trim Bezel – Locator and a Fixation Feature

  • 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

12Creation of Clip Locking Mounting Feature & Snap for the Trim Bezel

  • 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

132D Drawing Creation

  • Drafting work bench.
  • Creation of detail drawing for the Components
  • Views creations (basic view & section views)
  • Application of GD&T in drawings
  • Template settings

14Tooling Feasibility

  • Creation of Paring line
  • Creation of Tooling axis
  • What is undercut and how to solve it

15Molding Exercise 1

  • 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

16Molding Exercise 2

  • 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

17Plastic Defect

  • Plastic defects faced in automotive design
  • Real-time examples and solution for these designs

18Creation of IP Console Trim – Medium Complex Design

  • 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

19Assembly Work Bench

  • 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

20Door Trim Design with Master Section

  • 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

Course Five: Automotive Lighting Design CATIA v5

1Basic of Lighting & Software Overview

  • 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)

2Basic of Regulation & Start of Making Lamp

  • 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)

3Advance Level of Regulation with 3D Model & Plastics Introduction

  • 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

4Basic Tooling Check & Drawing Making

  • 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

Course Six: Automotive Seating Design using CATIA v5

1Introduction to Automotive Seating

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

2Current Fashion/Trend

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.

3 Component of Seats

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

4Component Details : Foam

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

5Component Details : Structure

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

6Component Details : Headrest

In this section, you will learn the following.

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

7Component Details : Trims

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

    8Component Details : Plastics

    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

    9Component Details : Armrest

    In this section, you will learn the following.  

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

    10Component Details : Mechanism

    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

    11Seat Testing

    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

    12Comfort and Innovation

    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

    13 Seat Related Issues

    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

    14DFMEA and PFMEA

    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

    16Program Life Cycle

    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

    Projects Overview

    Flexible Course Fees

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


    9 Months Access


    Per month for 10 months

    • Access Duration : 9 Months
    • Mode of Delivery : Online
    • Project Portfolio : Available
    • Certification : Available
    • Individual Video Support : 8/Month
    • Group Video Support : 8/Month
    • Email Support : Available
    • Forum Support : Available

    Lifetime Access


    Per month for 10 months

    • Job Assistance : Lifetime
    • Master's Assistance : Lifetime
    • Access Duration : Lifetime
    • Mode of Delivery : Online
    • Project Portfolio : Available
    • Certification : Available
    • Individual Video Support : 24x7
    • Group Video Support : 24x7
    • Email Support : Available
    • Forum Support : Available
    • Telephone Support : Available
    • Add-ons Industry Projects : 15
    • Offline Skill-Center Access : Available
    • Dedicated Support Engineer : Available
    • Paid Internship : 3 Months

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