Design Engineer Master's Certification Program

Design Engineer Master's Certification Program

  • 0% EMI Option Available
  • Pre-requisites : Mechanical, Aerospace & Automotive Engineers
Enroll Now View demo

Program Overview

The very first engineer on planet Earth was a design engineer. And they started off a revolution of which you and I are just part of. 

 

Design is the heart of any process, an idea that begins in the mind of an engineer is then translated onto a paper and from there it is fed into software, a long taxing process at the end of which something brand new is brought forth into the world. 

Design engineers are artists of engineering. They are the reason why the human race has raced to the stars and peered into the mysteries of the Universe. They are the reason why we have self-driving cars and they are also the reason why we don’t have individual jetpacks - yet. 

To become a design engineer beyond everything a student should have the capability to dream. To ideate. 

To think for themselves. 

To be an artist. 

 

To question if there is a career progression in design engineering is a fallacy, for how can there not be a demand for design engineers as long as humans are alive. 

 

Why are the prerequisites and learning outcome for a student after selecting the Master’s in Design Engineering program?

 

  • If the student has good creative skills and is enthusiastic about designing components.

  • Students will develop a keen understanding of how design engineers around the world design an engineering component. 

  • Design engineers need to understand how to incorporate aspects of manufacturing while drawing their designs, this program helps students understand these crucial attributes.

 

What are the employability options available to a student upon the completion of this program?

 

  • A fresher graduate can be recruited by firms into the position of a design engineer upon completion of this program.

  • A student can work in various domains of automotive and product design

  • Design engineer, CAD release engineer, Dimensional engineer are some of the positions that a student who has completed this program will become eligible for. 

Upon completion of this program, what are the various employability opportunities available to a student?

  • All automotive industries.

  • OEM’s.

  • Tier 1 and Tier 2 organizations.

 

With this Master's Course, we are offering two specializations for you to choose from. One with a Sketching Specialization and the other with a Manufacturing Specialization.

Under the Sketching Specialization, you will be offered:

  1. Automotive Sketching

  2. Automotive Class A surfacing using ALIAS

  3. Ultimate SOLIDWORKS Course

  4. SolidWorks Boeing 747 Design

  5. Automotive Sheet Metal Design using NX CAD

  6. Automotive Seating Design using CATIA V5

  7. Automotive Plastic Design using CATIA V5

  8. Automotive Lighting Design using CATIA V5

  9. Wiring Harness using CATIA V5

  10. Gap and Flushness in Automotive Body Design using CATIA V5

Under the Manufacturing Specialization, you will be offered:

  1. Ultimate SOLIDWORKS Course
  2. SolidWorks Boeing 747 Design 
  3. Automotive Sheet Metal Design using NX CAD 
  4. Automotive Seating Design using CATIA V5 
  5. Automotive Plastic Design using CATIA V5 
  6. Automotive Lighting Design using CATIA V5 
  7. Wiring Harness using CATIA V5 
  8. Gap and Flushness in Automotive Body Design using CATIA V5 
  9. Mold Design using SolidWorks 
  10. Automotive BIW Fixture Design using CATIA V5

Download syllabus

Design Engineer Master’s Program

Download Syllabus

GET COURSE COUNSELLING TODAY

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.

Request a Demo Session

Course One: Ultimate SOLIDWORKS course

1Introduction

In this course, you will learn about the solid modelling and surface modelling tools of the CAD software - SOLIDWORKS. SOLIDWORKS is a dynamic software used primarily in R&D sectors. SOLIDWORKS is widely used in the concept generation stage of production. It gives designers real-time results in product modelling.

 

Students from mechanical engineering can enrol in this course. In this course, you will be learning the fundamentals of concept generation.

 

At the end of this course, you will be fluent in both solid as well as surface modelling tools. After the completion of this course, you will become eligible for the role of a CAD engineer using SOLIDWORKS. This course is specifically designed for design engineers who are interested in the product concept generation phase. After the completion of this course, you will understand the basics of SOLIDWORKS including - part modelling, assembly modellings, photo-realistic renderings.

             

2Creating your own concept sketches

You will learn to create professional mood boards and initial ideation sketches in Adobe Photoshop. You will learn how to import & blend images, add watermarks and color. You will also learn how to design an American Chopper and how to render this design in Photoshop.

 

 



3Introduction to SOLIDWORKS and Mastering SOLIDWORKS User Interface

  • You will be introduced to SOLIDWORKS and will learn how to customize the shortcuts. You will learn solid modelling techniques in SOLIDWORKS while modelling the Transmission belt, Kickstand, and Fenders of an American Chopper. You will also learn how to add appearance to the parts of the bike. 

 



 

 



 

4Advanced Sketching and Solid Modeling

  • In this module, you will learn how to create advanced sketches using curved driven patterns and patterns such as sketches, projected, and composite curves. You will also learn how to create complex shapes while modelling the wheels, chassis, and engine.

 

 

5Assembly Techniques

  • You will learn the use of mates to provide relationships between parts in an assembly. You will also learn how and why advanced mates such as angle mates are provided to limit the rotation of parts.

 

 

6Rendering

In this module, you will learn how to add decals, lights, and cameras as a preprocessing step before the final rendering. You will be taken through the complete rendering process with PhotoView 360 and SOLIDWORKS Visualize using which you will be creating high-quality images during the final rendering.

 


7Surface Modelling

In this module, you will learn about the surface modelling feature in SOLIDWORKS. You will learn how to create a part using a reference surface. You will be taught advanced surface modelling features while creating various parts of the Yacht such as Hull, the Superstructure, and Seats. You will learn how to add decals and appearance for the parts and assembly.


Projects Overview

1Designing, Modelling, assembly and Photo-realistic Rendering of an American Chopper

In this project, you will sketch and build a complete road-ready Harley Davidson bike using SOLIDWORKS.
 
In this project you will learn about how to create cut extrudes, revolve cuts, lofts, circular patterns for modelling - Setting up of reference planes - curve generation - projected curve creation understanding how to insert the parts in assembly workspace - Creation of mates - Difference between float and fix parts - Width mates application 
 
You will also learn how to create photorealistic renderings with realtime appearances and views.
 
The following list is the key parts/models you will be dealing with under solid modelling using SOLIDWORKS.
  • Transmission belt, front & rear fender modelling
  • Chain, side stand & pedals modelling
  • Front & rear wheel modelling
  • Engine modelling
  • Chassis for American Chopper designing
  • Front fork designing
  • Oil tank designing
  • Creating the assembly of American Chopper
  • Performing the rendering on assembly created by using Photoview 360 and SOLIDWORKS Visualise as the rendering tool

2Modelling and Assembly of an American Predator Yacht

In this project, you will be able to sketch and build an entire American Predator Yacht using SOLIDWORKS.
 
In this project you will learn curve generation, surface creation from curves and sketches, different types of surfaces - boundary surfaces - lofted surfaces - filled surfaces - ruled surfaces- reference planes - surface trims - surface knit - move/copy surfaces - mirror surfaces
 
The following are the key parts/models you will deal with in surface modelling using SOLIDWORKS.
 
  • Blueprint setup
  • Modelling of propellers, radars
  • Modelling of the hull, garage doors
  • Modelling of rear seats. middle seats, front seats.
  • Creation of the superstructure
  • Final assembly model of the Predator Yacht


 


Course Two: SolidWorks Boeing 747 Design

1Introduction to Solidworks Surface Modelling Interface

  • Sketching tools
  • Surface modeling tools
  • Types of tools to create the surfaces
  • Blueprint setups

2Curve Generation

  • Spline
  • Spline vectors
  • Equal curvature for splines
  • Constraining the splines
  • Projected curve creation
  • Composite curve generation 

3Surface creation from curves and sketches

  • Types of Surfaces
  • Boundary surfaces
  • Lofted Surfaces
  • Filled Surfaces
  • Ruled Surfaces
  • Reference Planes
  • Surface Trims
  • Surface Knit
  • Move/Copy Surfaces
  • Mirror Surfaces

4Application of solid modelling

  • Revolve Boss
  • Extrude cut
  • Linear & circular patterns
  • Fillets
  • Chamfers
  • Split Bodies
  • Creation of wheels

5Introduction to Assembly Module

  • 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

Modeling & Assembly

Highlights

  • Blueprint setup
  • Modelling of fuselage and nose
  • Modelling of windshields, passenger windows and window wipers
  • Modelling of wings and stabilizers 
  • Creation of landing gears, wheels and wing flaps
  • Creation of nose gear and wheel sub-assembly.
  • Modelling Turbojet Engine
  • Final assembly model of Boeing-747 

 

 

 

 


Course Three: Automotive Sheet Metal Design using NX CAD

1Introduction

The Automotive Sheet Metal Design using NX CAD course provides an outline of the current Body in White (BIW) component design factors and detailed explanations about their significance to part function, cost, and reliability. In this course, the modern design methodology is examined, covering Design for Manufacturing and Assembly and how determining product end-use requirements is essential to creating successful contemporary products. 
 
Upon completion of this course, you will have a comprehensive understanding of the physical and theoretical design factors that must be considered during the creation of first-rate BIW components. You can start your career as a design engineer in any sheet metal domain and with 2 to 3 years of experience, you can become a full-fledged BIW engineer.
 
 

2Vehicle development cycle

This is an introductory session where students are introduced to the basics of automobiles along with different models of car bodies. Students will also learn about the different stages of vehicle development that a car will go through before reaching the customer. Students will also learn about the three years of development activity.

3Basics of Automotive Body in White

  • In this session, the student will be introduced to the basics of automotive BiW. The basics of steel and its properties are covered in details because steel is an important component used in automobiles. The steps that are followed in the selection of the material will be discussed as well. Studnets will be given an introduction into the cross-functional teams and the need to coordinate with them along with examples of master sections and 3D components of the parts for easy and clear understanding.

 


 

4Design Methodology of a Hood, Fender, Roof, Back Doors, and Side Doors

We will focus our attention 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

 

5Case study - Converting - RUECKWANDTUER INNER PANEL

 

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

 

6Design 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.

 

7Process 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

1Hood Design

  • In this particular project, you will be working on designing the inner panel of the hood of, according to euro cap standards and ensure that the designed part can be manufactured.
  • 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.

 

2Fender 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 that need to be satisfied for the deep drawing process.

 

3Roof Design

  • In this particular project, 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.

 

4Tailgate Design

 

  • In this project, you will develop the inner panel of a tailgate by suggesting a tooling direction. While also ensuring 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 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

    15GD&T

    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

    Project 1

    Highlights

    The Cad provided is a IGS file without any history. It is front row back foam. Use Under build / Over build technology. Make use of the foam terminology. Make foam parametric and use standards for making the parts.

    1 – The Complete design should be parametric.
    2 – Use Best Practices as Explained.
    3 – Use of best practice and maximum use part design.

     

    The Cad provided is a IGS file without any history. It is front row cushion foam. Use Under build / Over build technology. Make use of the foam terminology. Make foam parametric and use standards for making the parts.

    1 – The Complete design should be parametric.

    2 – Use Best Practices as Explained.

     

    Project 2

    Highlights

    The Cad provided is a IGS file without any history. Remaster the Solid using best practice as per below :


    1 – The Complete design should be parametric and by changing any dimension the complete Part should get updated.
    2 – Use Best Practices as Explained
    3 – Use Part Design work Bench.
    4 – Use minimum number of Command for making the part.

    The Cad provided is a IGS file without any history. Remaster the Solid using best practice as per below :
     
    1 – The Complete design should be parametric and by changing any dimension the complete Part should get updated.
    2 – Use Best Practices as Explained
    3 – Use Part Design work Bench.
    4 – Use minimum number of Command for making the part.
     

    8 D – Problem Solving

    • For a program launched in June 2020 we are facing a issue , the H Point of the Seat is not as per the OEM given value . The issue is observed in 56 car Seat set out of total production of 3250 cars.
    • The issue is observed in Foam. The Foam Hardness is not as per Specs.
    • Use 5 M, Pugh, and other technical logical reasoning ways to solve the issue.

     

    1 – A seat need to be designed for which track peel out strength need to be calculated. The hand calculation need to be done for which following details are provided :
    H – Point : X – 1175.4 mm , Y – 337.5 mm , Z – 390 mm
    Weight of the seat : - 18 Kg
    CG – same as H – Point
    Alpha Angle : 3 Degree
    Beta Angle : 3.7 Degree
    Mounting Point : 
    Point 1 : 
    X - 1093 mm
    Y – 290 mm
    Z – 298 mm
    Point 2 : 
    X - 1169 mm
    Y – 390 mm
    Z – 307 mm


    Calculate the strength of the Track (Peel Out Strength) required.


    * Assume data which are not provided in the above and make hand calculation with formula so that can be updated with change in any value.

     

     


    Course Five: Plastic Design using CATIA V5

    1Design Overview In Automotive Industry

    You will learn about the following topics, 

    • Product life cycle
    • Design life cycle

    2Plastics in Automotive Industry

    You will learn about the following, 

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

    3Introduction to CATIA

    You will learn about the following,

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

    4Sketcher workbench

    You will learn about the following, 

    • Commands, 
    • Rules to follow
    • Working in exercise

    5Part Design Work bench

    You will learn about the following, 

    • Pad, pocket
    • Working on exercise

    6Advanced part design

    You will learn about the following, 

    • 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

    You will create a PCB Bracket using Boolean operations

    8Surface design work bench

    You will learn about the following, 

    • Commands (Types of Sweep)
    • Working on exercise
    • Draft analysis
    • Working on surface exercise

    9Advanced Surface design work bench

    You will learn about the following, 

    • Commands 
    • Creation of Closed body, Thickened body
    • Parting line, parting surface

    10Creation of Trim Bezel and add thickness to it

    You will learn about the following, 

    • How to create a tooling direction and do the draft analysis to ensure the part can be taken out of tool
    • Adding the 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 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

    1Development of Car side door switch bezel

    Creating the CAD model of switch bezel from the following inputs 

    • Given Class A surface 

    • Plastic component thickness

    • Draft angle requirements

    • Create the draft direction for manufacturing using the injection molding technique 

    • Class B creation by maintaining a constant thickness 

    • Closing surface creation based on proper draft angle and parting line for core and cavity design 

    2Coin Holder

    Creating a solid model of coin holder from given Class A inputs


    • Check for draft analysis and make modifications 

    • Modify class A to meet the requirements. Prepare a report of changes made to Class A

    • Follow the procedure to create the solid model following plastic component design  techniques 

    • Check if the product can be manufactured by using draft analysis.

    3B pillar cover

    Create a B pillar from the given class A with engineering features

    • Create a solid model from the given class A by following plastic design rules 

    • Prepare dog houses and locators for matching the part with main B pillar 

    • Create the location for proper fixing of part 

    • Add rib feature to add strength to part 

    • Do draft analysis with respect to main tooling direction and slider direction.

    4Heat Staking

    Creating heat stakes for joining the plastic door applique to the metal substrate


    • Design the 4 way and 2-way locators for the plastic applique 

    • Understand the heat staking process

    • As per the design rules design the heat stakes to join the door applique with the metal part. 


    Course Six: Automotive Lighting Design using 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

    3D Drawing

    Highlights

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

    Tail lamp design

    Highlights

    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 Seven: Wiring Harness 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

    The Engine

    Highlights

    Route the wiring harness on the given engine and prepare to flatten view drawing in CATIA V5. Application of all packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply protection coverings as required.


    Car Body

    Highlights

    Route the wiring harness on the given car body and prepare flatten view drawing in CATIA V5. Application of all packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.



    Course Eight: Gap and Flushness in Automotive Body Design using CATIA V5 

    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

    12Conclusion

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


    Sketching Specialization Course One: Automotive Sketching

    1Introduction

    This is an introductory week. We will first look into what exactly is Design and then try opening it up with its family tree & branches as Automobile Design is a categorized part of Industrial Design. So, the entire process of it will be explained. We will also be discussing what will be the job of a designer in this role? We will also cover the history perspective along with evolution in design. And towards the end of the week, we will be looking into trends in Elements of Design. Then we will move on to Shape & Form design & its differences.

     

    • What is Design?
    • Overview- Industrial Design & Introduction – Industrial Designer
    • Overview- Automotive Design & Introduction- Automobile Designer
    • Design Process-Introduction
    • The Basic Design Process 
    • Important roles in the Design Process
    • History of Automobiles
    • Historical perspective on Car Design
    • Evolution of Design
    • Trends in Automobile Design
    • Elements of Design
    • Shapes & Form in Design
    • Introduction to Shapes & Forms
    • What are Forms?
    • Difference Between shape and form

    2Shape transformation and translation

    This week, we will be having a recap of the content we learned last week. This week, we will give more emphasis to form design topics, we will look into how to form design is used to build forms, Shape Translation & Transformation. The two important topics of this week are “Elements of Design” & “Principles of Design” teaching. We are giving more importance to these topics as they help us understand the design philosophy.

    • Transformation
    • Form Design-Continuation
      • Deconstruction
      • Forms in Automotive
      • Speed forms
    • Elements of Design
    • Principles of Design

    3Introduction to car design

    This week, we will be introducing you to how exactly the exterior body of a car is done. Once this is done, we will move into the aspects that cover automotive design. We will be looking into the entire exterior terminology. The week’s videos will also help you understand the industry language for those parts. We will be covering the engineering aspects later. You will finally be starting your practice to generate freehand sketching

    • Automotive Design- Body Styles, Layout, Proportions and Themes
    • Automotive Exterior Terminology7
    • Engineering Aspects
    • Introduction to freehand sketching of simple geometries

    4Introduction to isometric and perspective

    This week, we move on to a rather peculiar phenomenon or concept of drawing- perspective. But first, we will have a look at how things work in isometric and then we will start with different types of perspectives. Then once completed we will start sketching in perspective. This will help us understand what are the different parameters one needs to keep in mind while drawing each and every sketch. Moving to a car sketching block, while making one in perspectives it is vital that we understand how it affects the angle.

    • Isometric perspective - Working with Isometric grid
    • Types of perspectives
      • 1 point
      • 2 point
      • 3 point
      • Multipoint
    • Learning sketching in perspective: 1 point, 2-point & 3-point perspective.
    • Working with perspective Grid
    • Sketching car block in 1, 2 & 3-point perspectives freehand
    • Exterior and Interior Design
    • Understanding Exterior proportions
    • Sketching car side view proportion boxes- Sedan, SUV, Sports car, compact car & truck

    5Sketching of Car’s Front and Rear Views

    This week, you will be taken up a bit with ¾th perspective sketching, later on, you will learn about aesthetics. It will also give you an idea about the important vehicle ergonomics & packaging. After that will cover the technical side, and learn how to make a technical drawing. Coming to the Artistic side we will understand the basics to make different shapes & forms to understand the surface.

    • Sketching car ¾ front view, ¾ rearview Box as per proportions
    • Automotive Aesthetics
    • Vehicle Ergonomics
    • Vehicle Packaging & Benchmarking
    • Technical Drawing
    • Understanding Surface Shapes & Form basics

    6Shading & Basic Reflections

    This week, we will start with the basics of shading & reflections. Then after that will try a technique to render with different mediums. Will learn how a project basis is formed by desk & market research. Then coming to the user research, you will be learning how to make a design & mood board depending on your requirement and personality. Once completed we will take inspiration and create forms. We will then try to doodle and draw different shapes. And then finally we will see how a car is sketched by a step by step guide.

    • Basic Rendering Technique using a different medium
    • Desk Research & Market Research
    • User Research- Target User
    • Design & Mood Board- Inspiration Board
    • Inspirational Driven form
    • Doodle & Draw
    • How to draw Car side view- A step by step guide

    7Introduction to sketching as a communicating tool

    This week, you will learn how to use sketching as a tool to communicate. After that, we will go on to generate new forms and will look at techniques of how to do it. We will also learn about building concept form and the classification of sketches. We will then move on to a step by step guide to making cars in 3/4th perspective views while incorporating concept forms.

    • Form Generation Methods & Techniques
    • Sketches Classification & Basic – Ideation Sketches, Exploratory Sketches
    • Creating Concept forms
    • How to draw Car ¾ views- A step by step guide

    8Understanding lights and materials

    This week, you will try to make a photorealistic render. Then we will move on to understanding how lights & materials work on surfaces. We’ll try rendering techniques & implement all of the learning in the first Design Project.

    • Photorealistic Rendering
    • Reflection as on Car surfaces- Pencil Rendering & Marker Rendering
    • Design Project- 1 (1 week)
    • Design a Family Sedan. Keeping the brief in mind.

    9Introduction to Automotive Interior Design

    This week, you will be introduced to the interiors of the car. Here, you will learn about crucial ergonomics and interior occupant packaging. We will also look into the design for the 95th percentile rule. And at last, we will have a brief look at the Panels & Consoles

    • Car Interior Ergonomics- Crucial Role
    • Design for 95th percentile
    • Vehicle Packaging & Benchmarking
    • Understanding the interiors-Occupant Packaging
    • Introduction to Interiors- Instrument panel & Consoles- Brief

    10Sketches Classification & Basic – Explanatory Sketches and Persuasive sketches

    This week firstly will learn another classification of sketches and will start with the basics for the interior. Will have a look at the interior elements to understand the principle behind each element. After that, I can focus on sketching the interior as a whole. A study of trend Analysis & forecasting to learn about the upcoming trends so it is easy to predict the future.

    • Understanding the Interior Elements
    • Back to Basics- Forms & Shapes
    • Interior Sketching- 1 Detailed Interior Components
    • Trend Analysis & Forecasting

    11Automotive Technologies

    This week you will be learning about the relationship between automotive technologies and design. We will then be moving to the interior as a whole, here, we will look into each element and discuss its role while experimenting with it with different mediums. We will also be having a lesson on sketching with a sketchbook. So, you sketch directly onto your pc digitally.

    • Interior Sketching- 2 Detailed Interior Components
    • Different mediums for sketching- Explorations & its Effects
    • Digital Sketching- Sketchbook

    12Design Project

    This week before introducing something new, you will be getting an assignment. You will be making an interior of a car with all the elements. Later on, we will move to digital data & See how to render a car in a sketchbook.

    • Design a Certain type of vehicle interior with all the requirements of Interior needs.
    • Effectiveness of Digital Work & Refinements
    • How to Render cars in sketchbook

    13Nature and form, Biomimicry in transportation design.

    This week you will understand the influence of nature in form. You will learn the use of biomimicry in design and will implement it in your design. As nature is the best creator. So, this is again a small project in which you will find and adapt to what nature has to offer. And Make something unique.

    • Designing a vehicle while replicating a reptile or any mammal
    • Taking and breaking down its characteristics and using it in your own vehicle.
    • It can be a combination of 2 or a single
    • The characteristics of that reptile or mammal should be highlighted.

    14Products and brand management

    This week we will again start with a new topic. Here, you have to understand Product & Brand management. The main reason we are focussing on it is because it will help you to create a peculiar product for a potential customer. Later on, we will move onto a new project in which we will redesign a certain car, with its brand intact.

    • Redesigning an existing vehicle (pre-existed or current)
    • Understand the brand what they offer or the reason why they made that particular Vehicle.
    • Propose your Ideas while keeping the form and design intact from that original vehicle.
    • When you look at both of them the resemblance should be there.

    15Transportation Design- design of a minimised roadster with a complete interior and exterior.

    In previous weeks, you have covered several Projects in which a particular topic was only in play. This week we will be doing another project which is bigger at play and has all that you have learned. Start with a design process. This particular week we will decide the concept and ideation, later on, we will refine the design and finalize the exterior. 

    • Exterior Preliminary Sketches
      • Initial sketches for concept generation and ideation for exterior or have an idea in mind what you will propose.
    • Exterior Refinements & Finalization
      • Status updates on whatever changes or refinements suggested on the exterior design & finalize exterior Design first

    16Interior design

    This week is an extension of the previous week. In this, you will be focusing on the interior part of the car. As the exterior of the car is finalized now with the same process, design the interiors. Start with preliminary concepts and then finalize the interiors.

    17Transportation design project 2

    This week again you will start with a new project. This will be again for 2 Weeks in which the entire process of Research, Boards & Finalization will be followed. We are giving more emphasis on projects as this is a subject which can only be learnt with hands-on practice and this way you learn and get used to things happening in the industry. For this, we are actually going to design something for the year 2033. In which a lot will be depending on the research that you will do. A certain brief will be provided to you so you actually go on and work from the basics. You will be working on a tight timeline so plan accordingly.

    • Mobility Design 2033- Decide your Concept 2033
    • Find a problem, build a solution, think of a concept, decide an action plan, propose proposals and presentations.
      • Design Research- Brand Identity, Target Customer, Concept
      • Sketch Presentation- Form Sketches, Proposal Sketches
      • Rendering- Selected Sketches, Final Rendering
    • Exterior Design
      • Exterior Preliminary Sketches Initial sketches for concept generation and ideation for exterior or have an idea in mind what you will propose.
      • Exterior Refinements & Finalization Status updates on whatever changes or refinements suggested on the exterior design & finalize exterior Design first

    18Interior design

    Following last week, the exterior is completed and now we start with the interiors. Firstly, try to focus on the elements, after that focus on the design part. Be free with your ideas! as there is no limit on thinking. We are creating for the future. But, think realistically. At last, get everything rendered in a sketchbook and submit it as a presentation.

    • Following are the checkpoints to be covered for the same:
      • Interior Preliminary Sketches
    • Initial sketches for concept generation and ideation for interior
      • Interior Refinements & Finalization

    19Introduction to transportation design (final project 1)

    Welcome to the final project. This week, we are going to start this project which will be completely your own. You will make a brief of what you want to make, decide your users, and follow the entire process of design to take your idea to a final stage.

    • Make your Own Brief
    • Design Research- Desk & Market Research
    • User Research- Target Customer, Design / Mood & Inspiration Board
    • Research the Automotive technologies
    • Prepare a Trend Analysis & Forecasting Report
    • Build for a brand- Product & Brand management Report

    20Design Brief- sketching after Ideation, Inspiration and Exploration (Final Project 2)

    As the procedure for doing research and collection of data is clear to you, this week you will start with the conceptual phase by taking inspiration. You will then provide the ideations for your design. You have a lot of time to think and explore your ideas. Try to solve/create something better or different from your design.

    21Exterior design finalisation (Final Project 3)

    This week, our main focus is to finalize the exterior design, the refinements have to be implemented early so that we can make technical drawings of it. Later on, we wish to start with the preliminary sketches of interior design if the entire exterior design is finalised

    22 Interior design sketching (Final Project 4)

    This week we start on the interior design aspect of your design. First, try to think of your vehicle and then start experimenting with the things that you need for your interior. Try to build a relation between interior & exterior and try to be more expressive by using different perspective views. Focus on interior components, the looks and functions. Do an ideation sketch so everything becomes clear.

    23Interior design finalisation

    This week is totally focused on finalising the interior design. The main focus is to finalise the direction of our ideation and purpose. Later on, work on refinements and finalize the interior with detailed Interior elements sketches.

    24Final Renders

    In this last week, you will do the rendering & produce your design within a presentation. So the entire design process is clear to someone who will look at the presentation. And in the end, we will be having a session where we will be discussing techniques to better present your product. We will also discuss techniques that we need to focus on while designing.


    Projects Overview

    Project 1

    Highlights

    1. Try to draw different shapes and assume the light, material and shade areas
    2. Trying photorealistic Rendering and submit one.
    3. Try the Reflection techniques with pencil and markers
    4. Complete the entire Design project with all the views with pencil shading. Try to explore your options.
    5. Basic Beginner rules for sketching & Practice

    Project 2

    Highlights

    1. Try to make sketches which explains a function & try to communicate idea by persuasive sketches

    2. First understand the interior elements & following the process using basics, try out different shapes for interior.

    3. Try to cover all the elements

    4. Make a report on trend analysis & Forecasting, Considering 

    Project 3

    Highlights

    1. Make a report on Automotive Technologies and there use in industry

    2. Make all the components of interior like Steering, door panel etc.

    3. While sketching tries to work with different mediums to explore the efficiency and quality

    4. Practice sketching on the digital media but stick to pencil n paper for now. First get your hands on this.

    5. Basic Beginner rules for sketching & Practice

    Project 4

    Highlights

    1. Complete the Design Project, again imagine the user and make an interior sketch.

    2. Try to Sketch directly into sketchbook and then use the tools to render by applying the same principles we covered in pencil & marker rendering.

    Project 5

    Highlights

    1. Submit a Report- Nature & Form- Research about what is going to be the problem and your solution from nature.

    2. Mention the reptile or mammal you are taking as inspiration, its properties. Point out the reasons, theory behind why or because of what reason It is like this. Ad how It is a best fit for your solution.

    3. Derive the Ideation, take inspiration, and come up with the Form and its functional usability and Finish this project. Request you not to copy.

    Project 6

    Highlights

    1. Submit the Report in which state a brand, year of vehicle & what was the brand offering during that time. Now, what has changed.

    2. Start with the brand & Redesign in a sense that at first looks they both look similar. Try to understand what the company, their Design language, brand identity, etc.

    3. Finish the project in a manner that a differentiation can be carried out of what was there, and what you made.

    Project 7

    Highlights

    1. Follow the Design Brief and completed the exterior for Minimised Roadster.

    2. Submit the finalized Design sketches or render it is up to you. If you are Comfortable in Sketching & Shading, those finalized sketches are also fine.

    3. Design interior with same design language & follow the same process

    4. Ideate Interior and Finalize a design which you thing well suits with your Design.

    5. For final submission you can make a presentation and put in your sketches. Rendering the interior is up to you with any medium. (Not necessary for this project)

    Project 8

    Highlights

    1. Prepare & Submit the report on the technologies which are currently in the market incorporated in the automobile industry and what are the future trends

    2. Depending on which what problems you think will be there and What is your solution.

    3. Follow the entire Design process of User Research, Target user, Make Design Boards- Mood Board & Inspiration Board.

    4. Exterior Design ideation, Explorations & Finalize your Exterior Design.

    5. Complete the entire sketch finalization of interior & Render the views.

    6.Submit a presentation of all the projects in which everything will be mentioned like all the boards, users & sketches for both interior & exterior and then final renders.

    Project 9

    Highlights

    1. Submit the entire presentation containing your Design brief- Explained

    2. Desk Research, Market Research, User Research (Provide separate links as well for Data research)

    3. Mood Board & Inspiration Board with Keywords

    4. Automotive Technologies, Trend Analysis & Forecasting Report

    5. Start with ideation if data is completed. 

    6. Submission of the Preliminary Sketches and mention of the direction that you want to go ahead with. Prepare a presentation so it is easy to check the entire Process, or you can make it an addition in the previous presentation

    7. Submission of Finalized exterior Sketches in the direction that you chose earlier.

    8. A technical drawing for the same with the entire packaging data.

    9. Addition in the previous presentation.

    10. Submission of Interior ideation & exploratory Sketches and mention of the direction that you want to go ahead with.

    11. Addition in the previous presentation

    12. Submission of Interior Finalized sketches.

    13. Addition in the previous presentation

    14. The necessary Final 3 views have to be submitted are Side view, front 3/4th quarter view & rear 3/4th quarter view. Rest you can do additional if you like.

    15. Submit the presentation containing all the process from start till the final

     


    Sketching Specialization Course Two: 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
    • G-2 - Curvature
    • G-3 - Curvature

    6Workflow 1: Concept Modeling

    • Introduction to Concept Modelling 
    • Construction Options Introduction 
    • Dimensions 
    • Overlay canvasses for design and presentation. 
    • Building with Curves & Surface Tools 
    • Modelling approaches and Surface distribution 
    • Working Accurately

    7Workflow 2: Concept Modelling

    • Overlay Canvass for design
    • Surface understanding by Three-quarter views.
    • Building with Curves & Surface Patching 
    • Modelling approaches and Surface distribution

    8Workflow 3: Concept Modelling

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

    9 Workflow 4: Concept Modelling

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

    10Workflow 5: Concept Modelling

    • 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 modelling

    • 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

    Modelling Project

    Highlights

    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 Modelling. Create Curve network as Required. Once Volume has completed the process of filleting should be applied to the entire model.

    Presentation Design Project

    Highlights

    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.

    Manufacturing Specialization One: Mold Design using SolidWorks

    1Introduction

    If you had the privilege of being in a FIAT Padmini, you would have noticed how the metallic interior and exterior stood out. It was built like a tank because of which the car was heavy. If you notice the cars running on the streets today, the interior and exterior have significantly more plastic components. Even if you take a look at many of the appliances that you use today, you would notice the rise in the number of plastic components. 

    In India, the rate of growth of the plastics industry is almost 16% per annum as per a report by British Plastics Foundation. The reports show that there is not going to be a drop in the rate anytime soon. With this, you can pretty much understand the importance of the plastics industry and the time and effort that goes into making a plastic component.

    We, at Skill-Lync, have come up with a course that will help you understand what you need to know to enter into this industry. This course is tailored in such a way that anybody with a basic grasp of any modelling software will be able to finish this course. 

    The course contains 12 weeks of curated content taking you through the very basics of SOLIDWORKS where we help you master all the commands required for you to start working on the tool. Following which you will be introduced to the basics of plastics and injection moulding where you will get a better understanding of the processes involved. We then take you through the steps involved in creating a basic mould for simple parts. Over the following weeks, you will be introduced to more complex concepts in mold design. 
    Through the duration of this course, you will be required to work on challenges that pertain to each week of content so that you get to work on the models that you see in the explanation videos as well as extra models that will challenge you to think ahead and use the concepts learned in the videos

    2Basics of Injection Molding / SOLIDWORKS Surfacing

    This section will cover 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
    • The current trends 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

     

    3Basics 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.

    4DFM and Defects

    In the third week, 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 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.

     

     

    5Parting Surface / Mold Design Tutorial 1

    In the fourth week, we will be studying the theory behind parting surfaces. The topics that will be covered are as follows:

     

    • What is a parting surface?
    • Types of parting surfaces such as flat, stepped, angled and profiled parting surfaces
    • Example cases where we will try to understand the selection of parting surfaces
    • Matching drafts
    • Shrinkage 
    • Inserts 



    In the SOLIDWORKS session, we will start with our first mold design tutorial. We will be covering 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

     

     

    6Sliders 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.

     

     

    7Gates 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 engravings are used in cavity



    Then in the SOLIDWORKS session, we will be creating a mold for a door bezel model. The 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.

     

     

     

    8Mold 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.

     

     

    9Mold 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.

     

     

    10Mold 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.

     

     

    11Mold 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 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.

     

     

    12Mold Design Tutorial 5 - Part 3

     

    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.

     

     

    13Mold 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 back plates.
    • 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

    Project 1

    Highlights

    For your first project on mold design, you will be working on creating a proper mold for a table fan stand. Though the table fan stand may appear to be a fairly common and simple product to manufacture, due to the presence of undercuts (explained in the course) in the model, it is actually not possible to manufacture the product using just two standard core-cavity mold blocks. In order to deal with external undercuts along with the creation of proper core-cavity mold blocks, creation of proper additional sliders is also necessary. The process of creation of sliders will be covered in the course for other models. The students will be expected to understand the concept of sliders applied on other models covered in the course, and then apply those concepts learned to the table fan stand model. Thus, working on this project would prove to be both challenging as well as provide insight and experience on how to use sliders while creating a mold for a component.

     

    Manufacturing Specialization Course Two: Automotive BIW Fixture Design using CATIA V5

    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 of 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

    Robot Welding

    Highlights

    1. Designing a Robot Welding Fixture
    - Developing the complete fixture assembly with all the necessary units (like pin unit, clamp unit, base unit, rough locators, etc) for the given BiW assembly


    - Preparing 2D assembly drawing and child part drawing for all the relevant parts of the fixture assembly

    - Preparation of BOM and BOP as a part of the output documentation

     

    Manual Welding

    Highlights

    2. Designing a Manual Welding Fixture
    - Developing the complete fixture assembly with all the necessary units (like pin unit, clamp unit, base unit, rough locators, etc) for the given BiW assembly

    - Preparing 2D assembly drawing and child part drawing for all the relevant parts of the fixture assembly

    - Preparation of BOM and BOP as a part of the output documentation

     


    Flexible Course Fees

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

    Basic

    9 Months Access

    $333

    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
    • Telephone Support : Available
    Premium

    Lifetime Access

    $466.2

    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
    • Dedicated Support Engineer : Available
    • Paid Internship : 3 Months

    You Might Also Be Interested In

    Related Courses

    See all

    Testimonials

    Companies hire from us

    See all

    Certification

    • 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

    SKILL LYNC WORKS TO GET YOU A JOB

    See all

    The Skill-Lync Advantage

    See all