Post Graduate Program inManufacturing Design

1. 01Automotive Plastic Design using CATIA V515 modules

   1. Design Overview In Automotive IndustryW01
      • In this session, you will learn
        • Product Life Cycle
        • Design Life Cycle
   2. Plastics in Automotive IndustryW02
      • In this session, you will learn
        • Types of plastics (Thermoset Plastics, Thermoplastic)
        • Engineering plastic Materials
        • Manufacturing Process
        • Injection Molding
   3. Introduction to CATIAW03
      • In this session, you will learn
        • Basic commands and operation
        • Save feature, pan feature, rotate feature, etc
   4. Sketcher workbenchW04
      • In this session, you will learn the following
        • Commands
        • Rules to follow
        • Working in exercise
   5. Part Design WorkbenchW05
      • In this session, you will learn
        • Pad and pocket
        • Working on exercise
   6. Advanced part designW06
      • In this session, you will learn
        • Boolean operations
        • How to work on a Boolean exercise
        • How to work on After Tool Go modification on Automotive components. (OEM Working procedures)
   7. 2D Drawing creationW07
      • In this session, you will learn to
        • Create a PCB Bracket using Boolean operations
   8. Basic Surface Design WorkbenchW08
      • In this session, you will learn the following
        • Commands (Types of Sweep)
        • Working on exercise
        • Draft analysis
        • How to work on a surface exercise
   9. Advanced Surface Design WorkbenchW09
      • In this session, you will learn the following
        • Commands
        • Creation of Closed body, Thickened body
        • A parting line and parting surface
   10. Creation of Door Switch Bezel and adding thickness to itW10
       • In this session, you will learn
         • How to create tooling direction and do the draft analysis to ensure the part can be taken out of the tool?
         • Adding the right thickness to the part and solving the issues.
         • Create the parting line for the bezel.
   11. Tooling FeasibilityW11
       • In this session, you will learn
         • What is a mounting feature?
         • How to create a locator and dog house?
         • Integrating the mounting features to the base part with Boolean operations
   12. Modeling ExerciseW12
       • In this session, you will learn
         • The Clip mounting feature is in Plastic design.
         • Design considerations for creating this feature
         • Tooling analysis for the clip feature
   13. Drafting WorkbenchW13
       • In this session, you will learn
         • Drafting workbench
         • Creation of detail drawing for the Components
         • Views creations (basic view & section views)
         • Application of GD&T in drawings
         • Template settings
   14. Mold Design ConsiderationsW14
       • In this session, you will learn
         • Creation of Paring line
         • Creation of Tooling axis
         • What is undercut and how to solve it
   15. Complex Mold Design ParametersW15
       • In this session, you will learn
         • Creation of simple mold for the Rear quarter trim Cupholder
         • What are core and cavity
         • Stripper, ejection, and system
         • Draft analysis
       • Designing a mold gives a good working understanding of the molding aspects of a component
2. 02Automotive Sheet Metal Design using Siemens NX CAD / CATIA V56 modules

   1. Vehicle development cycleW01
      • This is an introductory session where you will be introduced to the basics of automobiles along with different models of car bodies.
      • You will learn about the different stages of vehicle development that a car will go through before reaching the customer.
      • You will also learn about the three years of development activity that precedes the development of an automotive model.
   2. Basics of Automotive Body in WhiteW02
      • In this session, you will be introduced to the basics of automotive BIW.
      • You will be introduced to the basics of steel and its properties in detail as steel is an important component used in the construction of automobiles.
      • The steps that are followed in the selection of the material will be discussed as well.
      • You will be given an introduction to cross-functional teams that exist in an organization, and the need to coordinate with them along with examples of master sections and 3D components of the parts for easy and clear understanding.
   3. Design Methodology of a Hood, Fender, Roof, Back Doors, and Side DoorsW03
      • In this module, we will focus on the Hood, Fender, Roof, Side doors, and Back doors.
      • The design procedures for all the afore-mentioned parts can be summarized as follows,
        
        • Design Requirements
        • Functional Requirements
        • Regulations
        • Gap and Flushness Requirements
        • Safety Requirements
   4. Case study - Converting - Backdoor/Tailgate Inner PanelW04
      • In this module, we will present a real-life scenario where the effect of converting an inner panel from aluminium cast to the steel deep draw part will be shown.
      • Here is a quick summary of this case. The following design parameters were identified as critical and hence were fully described:
        
        • The seal surface width was the same as the aluminium liftgate
        • Tailgate outer parting was maintained as the same
        • Liftgate thickness was modified
        • Gap and flushness were maintained
      • You will be able to clearly understand these design parameters and the decisions that were made.
      • In this case study, the design guidelines were set through a series of CAE simulations.
   5. Design of key mechanism - Lock and StrikerW05
      • In this module, you will study the anatomy of a Locker and Striker mechanism.
      • In order to be a successful product development engineer, it is very important to understand in detail the development process and design requirements for even the smallest component.
   6. Case study Process and challenges with supplier manufactured partsW06
      • In this module, we will look at two case studies.
      • Both of these studies focus on supplier manufacturing practices.
      • We will discuss the design challenges faced by two Asian Automotive suppliers and then go over the solution methodologies
3. 03Automotive Wiring Harness using CATIA V510 modules

   1. Basics of Vehicle Electrical Distribution System & Wiring HarnessW01
      • In this session, you will learn
        • 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
   2. Introduction to CATIA V5 Electrical Workbench & Electrical Part DesignW02
      • In this session, you will learn
        • Customized settings for electrical environment
        • Wiring harness routing process for CATIA V5
        • CATIA V5 – electrical part design
   3. Electrical Part DesignW03
      • In this session, you will learn
        • Clip/clamps/support part definition
        • Backshell definition
        • Protective covering definition
   4. Harness Assembly & Installation – Part 1W04
      • In this session, you will learn
        • Preparation of harness assembly
        • Creating the wire harness geometrical bundle
        • Inserting harness components into a geometrical bundle
        • Positioning your inserted electrical parts
        • Connecting & Disconnecting electrical components
        • Defining the wiring harness routing
   5. Harness Assembly & Installation – Part 2W05
      • In this session, you will learn
        • 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
   6. Harness Assembly & Installation – Part 3 W06
      • In this session, you will learn
        • 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
   7. Wiring Harness FlatteningW07
      • In this session, you will learn
        
        • Wiring harness flattening workbench
        • Flattening workbench settings
        • Flattening the 3D harness assembly
        • Modify flatten assembly
        • Saving the flatten files
        • Drawing, creation & contents
   8. Component Specifications & Selection GuideW08
      • In this session, you will learn
        • Wiring harness component specifications & selection parameters
        • Available suppliers in the market (India)
   9. Wiring Harness Routing & Packaging Basics – Session 1W09
      • In this session, you will learn
        • Definitions
        • Routing & packaging process
        • Design criteria (generic) for wiring harness
        • Packaging rules & best practices
        • Guidelines for battery cables routing
   10. Wiring Harness Routing & Packaging Basics – Session 2W10
       • In this session, you will learn
         • 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
4. 04Geometric Dimensioning and Tolerancing7 modules

   1. Introduction to GD&TW01
      In this module, you will study GD&T and its uses. After your first class, you will be able to understand the basics such as:

      • Difference between traditional dimensioning and GD&T
      • Benefits of GD&T
      • How to read a feature control frame
      • Technical standards- ASME Y14.5M-2009
      • Different symbols used in GD&T, cover, and feature of size
   2. Rules, Symbols, and Form TolerancesW02

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

      • Rule No. 1 (i.e. Taylor principle a.k.a envelope principle)
      • Rule No. 2 (Regardless of feature size)
      • 14 symbols used in GD&T
      • Flatness, straightness, cylindricity, and circularity tolerances
      • MMC, LMC, and RFS conditions
      • Various examples for form tolerances
   3. Datums, Modifiers, Virtual ConditionW03

      In this segment, you will study the following topics:

      • What are datums and how to apply datums to parts
      • Datum reference features
      • Datum feature modifiers
      • How to calculate virtual condition
      • Conjugated datums
   4. Orientation Tolerance and Profile ToleranceW04

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

      • Profile of a surface and profile of a line
      • Perpendicularity tolerance, parallelism tolerance, and angularity tolerance
      • Composite profile tolerance
      • Various examples for orientation and profile tolerances
   5. Position ToleranceW05

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

      In this section we will go through:

      • Understanding true position
      • Projected tolerance
      • Composite tolerances
      • Tolerance zones- cylindrical, rectangular, spherical
      • Examples of position tolerance
   6. Co-axiality, Symmetricity, Run-outsW06

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

      You will learn:

      • Coaxiality
      • Symmetricity
      • Circular and Total Run Outs
      • Examples
   7. Understanding GD&T DrawingW07

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

5. 05Automotive BIW Fixture Design using CATIA V510 modules

   1. Introduction to BIW-FixtureW01
      • In this session, you will learn
        • Definition of BIW, Jigs, & Fixture
        • BIW-Nomenclature
        • Types of Fixtures & their applications
        • BIW stations & their uses
        • Basic terminologies
   2. BIW-Fixture BasicsW02
      • In this session, you will learn
        • Project activities
        • Different welding processes
        • 3-2-1 Principle
        • Body planes
   3. Pre-Design ProcessesW03
      • In this session, you will learn
        • Design methodology
        • Structuring a design tree
        • Different types of fixture units
   4. Units Design-1W04
      • In this session, you will learn
        • Different types of Pin Unit Design
        • Different types of Clamp Unit Design
        • Different types of Rest Unit Design
   5. Units Design-2W05
      • In this session, you will learn
        • Dump Unit Design
        • Slide Unit Design
        • Base Unit Design
   6. Finishing of the designW06
      • In this session, you will learn
        • 3D-finish
        • Rough locators
        • Pneumatic routing
        • Valve banks & selection
        • Gun study
        • Sensors & selection
   7. 2D-Detailing Basics W07
      • In this session, you will learn
        • Drawing templates
        • Angles of projection
        • Basic GD&T used in fixturing
        • Scaling & views
        • Various detailing patterns
   8. 2D-Detailing W08
      • In this session, you will learn
        • Key Sheet detailing
        • Unit detailing
        • Child parts detailing
   9. 2D-Detailing - Child Part & BOMW09
      • In this session, you will learn
        • Child parts detailing
        • Material selection
        • BOM Preparation
   10. Documentations, Sequence Sheet & Process SheetsW10
       • In this session, you will learn
         • Creation of BOM sheets
         • Creation of BOP sheets
6. 06Mold Design using SOLIDWORKS12 modules

   1. Basics of Injection Molding / SOLIDWORKS ModellingW01
      • In this week, the following topics are covered.
        
        • Injection molding process
        • Plastic processing methods
          • Rotational molding
          • Extrusion
          • Vacuum forming
          • Blow molding
          • Gas-assisted injection molding
        • Mold cycle and the factors affecting it
        • Thermoplastics and thermosets
        • Current trends in the industry
        • Types of plastics
        • Properties of plastics
        • Selection of plastics
        • Basics of sketching
        • Basics of using features in SOLIDWORKS
   2. Basics of Mold Design / SOLIDWORKS SurfacingW02
      • In this session, the following topics are covered.
        
        • Product development process
        • Various departments in plastic manufacturing industries and the workflow
        • Parts of mold
          • Core, cavity, guide pillar, sprue, register ring, guide bush, ejector pin, return pin, spacer blocks, core plate, cavity plate, ejector plates, etc.
        • 2 plate & 3 plate molds
        • Drafts
        • Parting lines
        • Various surface tools for designing in SOLIDWORKS
   3. DFM and DefectsW03
      • In this module, we will be covering theory related to various concepts and terms used in mold design.
      • The topics we shall cover are:
        • Concept of machine tonnage and its calculation
        • DFM study
          • Gate point, wall thickness, cores, tolerance, venting, ejector pads, inserts, ejector inserts, guide pillar, support block, relief, free play inserts, multi-gate position, and flow leader.
        • Defects in mold design process
          • Short shots, flash, weld lines, sink marks, blisters, jetting, burn marks, warpage, gloss differences, hesitation, overpacking, and unbalanced flow.
   4. Parting Surface / Mold Design Tutorial 1W04
      • In this module, we will be studying the theory behind parting surfaces.
      • The topics that will be covered are as follows:
        
        • Parting surface
        • Types of parting surfaces
          • Flat stepped
          • Angled
          • Profiled
        • Example cases to understand the selection of parting surfaces
        • Matching drafts
        • Shrinkage
        • Inserts
        • Mold design tutorial
          
          • Doing draft analysis for the model
          • Creating parting lines
          • Creating shut-off surfaces
          • Creating parting surfaces
          • Create basic mold blocks
   5. Sliders and Ejection System/ Mold Design Tutorial 2W05
      • In this module, we will be looking at the topic of sliders and ejection systems.
      • The topics that will be covered are:
        • Need for sliders and their working
        • General types of sliders
          • Sliding split type molds
            
          • Angular lift pin type molds
        • Methods of actuating the sliders
          • Finger cam
          • Dog leg
          • Cam track
          • Spring
          • Hydraulic actuation
        • Concept of slider locking
        • Types of ejector systems
          • Pin
          • Sleeve
          • Stripper
          • Blade ejector systems
            
        • Creating a mold for the outer cover of a disposable camera
          • Creating parting lines, shut-off surface, parting surface, and mold blocks for the model
          • Creating ejector pins for the mold
          • Creating inserts for the mold
   6. Gates and Runners / Mold Design Tutorial 3 - Part 1W06
      • In this module, we will be learning about runners and gates.
      • The various topics covered are as follows:
        • Types of gates: Sprue, edge, tab, overlap, fan, disk, ring, spoke, film, pin, submarines, and cashew gates
        • Runner diameter calculation
        • Types of runners
        • Runner configurations
        • Why engravings are used in cavities?
      • Creating a mold for a door bezel model
        
        • Creating the parting lines, shut-off surfaces, and parting surfaces of 3D profile for the model
        • How to work in assemblies and how to arrange files in a specific format?
        • How to align the sprue of the mold with the origin of the assembly?
        • How to select proper dimensions for the mold blocks?
        • Creating mold blocks for door bezel
   7. Mold Design Tutorial 3 - Part 2W07
      • In this module, we will continue working on the door bezel model from the previous session and learn the following topics:
        • Locating undercuts in the model
        • Understanding the use of sliders in solving the undercut issue
        • Creating slider split
        • Assigning proper dimensions to the slider
        • Editing the core cavity blocks according to the shape of the slider
        • Creating bolts, washers, and locking mechanisms for the sliders
   8. Mold Design Tutorial 4 - Part 1W08
      • In this module, we will start creating a mold for a CPU fan case model and we will learn the following topics:
        
        • Complex parting line selection
        • Providing correct matching drafts for the model
        • Creating the core-cavity surfaces for the model.
        • Aligning the sprue location
        • Selecting dimensions
        • Creating the mold blocks for the CPU fan case in the assembly
        • Adding reliefs for the core-cavity blocks
   9. Mold Design Tutorial 4 - Part 2W09
      • In this module, we will continue working on the CPU fan case model and we will learn the following topics:
        
        • Locating undercuts in the model
        • Creating a slider split for the undercuts
        • Assigning proper dimensions for the sliders
        • Providing reliefs for the sliders
        • Creating inserts for the model
   10. Mold Design Tutorial 5 - Part 1W10
       • In this module, we will start creating a mold for a plastic knob model and we will learn the following topics:
         • Creating the parting line, shut-off surface, and the parting surfaces for the plastic knob model
         • Automatic and manual shut-off surface creation
         • Core-cavity surfaces for the plastic knob model
         • Sprue alignment
         • Selecting dimensions and creating the mold blocks for the plastic knob in assembly
         • Theories behind the cooling channels for a mold
   11. Mold Design Tutorial 5 - Part 2W11
       • In this module, we will continue working on the plastic knob model and we will learn the following topics:
         • Creating multiple inserts for the model
         • Creating holes for fixing the inserts
         • Locating undercuts and creating a slider split for it
         • Complex slider creation
         • Assigning proper dimensions for the slider
   12. Mold Design Tutorial 5 - Part 3W12
       • In this module, we will continue working on the plastic knob model and we will learn the following topics:
         
         • Creating an ejector system
           • Angled ejector pins
           • Reliefs
           • Ejector plates
           • Ejector backplates
         • Making channels for plastic injection
           • Sprue
           • Runner
           • Gate
         • Use of air vents in a mold
         • Creating channels for air passage
         • Selection of the dimensions and positions of the cooling channels
         • Creation of cooling channels

Automotive Wiring Harness using CATIA V5

Wiring Harness on Engine

This project deals with the design of the wiring harness of the engine. Here, the students will perform wiring harness routing, flattening and 2D drawing creation for the Engine mo…

Automotive Wiring Harness using CATIA V5

Wiring Harness on Car Body

This project deals with the design of the wiring harness on the car body. Here, the students will perform wiring harness routing, flattening and 2D drawing creation.

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Hood

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

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Fender Drip Area

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

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Roof Assembly

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

Automotive Sheet Metal Design using Siemens NX CAD / CATIA V5

Designing of Tailgate

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

Mold Design using SOLIDWORKS

Creation of Mold for a Table Fan Outer Casing

This project is about creating the mold for a table fan outer casing with consideration of side cores.

Mold Design using SOLIDWORKS

Mold Design of Fan Bezel 

This project is about designing the mold for a fan bezel. In this project, you will be extracting Core & Cavity for a fan bezel.

Automotive Plastic Design using CATIA V5

Design of Coin Holder

In this project, you will design a coin holder plastic trim part from the given Class-A surface. Check if the product is manufacturable.

Automotive Plastic Design using CATIA V5

Design of Heat Staking

In this project, the students will design heat stakes for joining the plastic door. The students will apply the 3-2-1 principle for designing the plastic applique.

Automotive Plastic Design using CATIA V5

Design of Switch Bezel

This project is about the development of a car side door switch bezel. You will be creating the CAD model of the switch bezel from the given inputs.

Automotive Plastic Design using CATIA V5

Design of B-pillar Cover

The project deals with the design of a B-pillar cover. The students will create a Plastic B pillar trim from the given class-A surface.

+ 4 more projects in the full syllabus