Fender Design

Objective: Design attachment features for a car front fender using NX CAD software.

Introduction: The car's front fender is one of the outer body panels present on the front side of the car. It provides attachment features(mounts) for the bumper, A-Pillar, and sill.

There are two types of front fender design used in cars i.e. full bumper type and half-bumper type as shown in the figure below

Full bumper-type front fender of Rolls Royce Phantom Half bumper-type front fender of Mahindra Bolero

In this project, A class surface of the front fender was provided along with the master section. Attachment features like Sill mounting, A-Pillar mounting, and, bumper mounting were carved out as per the master section.

Design Process

Importing A-class surface into NX-CAD software and examining it for any open area. As provided A-surface had multiple surfaces so therefore all the surfaces were joined by using sew command to make it a single body.

Drip Area mounting Design

Drip mounting is used to mount the fender with the engine compartment. It is designed in such a manner that the mounting joint must not be visible to customers from the outside. Also, it must provide enough tool workability for service and repair. Embosses were provided to improve NVH performance. Flange length was taken as per in accordance with the master section i.e. 150mm from the bumper mount and 120mm from the A-pillar mount.

Other mounting flanges were designed as per rough estimation due to the unavailability of data related to A-Pillar, bumper, and sill area design. Mounts were designed throughout the wheel arch of the fender for mounting plastic liner by means of pushpins.

After completing the design of all mounting flanges thickness of 0.5mm was provided to the fender panel by using thicken command.

Isometric View

Front View

Top View