Design and development of automotive fender
Design of Front Fender for car :
A Fender is the accessory of a car, truck or bike that surrounds the wheel properly. The basic function of car fenders is to keep dirt, pebbles and debris from being tossed into the air by the tire. Over time, the meaning of a fender on a car depends a lot on the place where it is fixed; fenders are on the front wheel while quarter panels are in the rearwheel (minusduallys which still describe the back as a “fender”). Tires made in factory, generally have an uncovered curve over the top of the tire. This is the place which is responsible to toss the debris in the air and hence it should be covered.
1.Front fender( Right)
2.Front Fender(Left)
3.Rear Fender (Right)
4.Rear fender(Left)
Mastersection for Design considerations :
Types Of Fender from history :
1.Full bumper type
Majorly now a days most of the companies are using half bumper type, the main reason is if we using full bumper type the material wastage is more further it will effect on cost. So to reduce the blank wastage we are using half bumper type. By slightly increasing the blank overall size we can produce two half bumpers instead of one full bumper.
2.Half bumper type
Like how we can have good scrap management. Like this we are reducing some amount of metal and reducing the weight, it will increase the performance of vehicle. As we are reducing the steel metal we will have more plastic material on bumper.
Example Image of full bumper type
Example image of half bumper type
Fender having 5 mounting points.
- Body side
- A Pillar mounting
- Sill mounting
- Cowl mounting
- Drip Area
At the mounting points we are using fasteners to mount this fender. Any way the fasteners will close by the plastic parts so we don’t see any ugly region from outside.
Drip Area :
In out of 5 mounting points drip area is the very critical design.
The distance 200mm is at the cowl mounting region there are wiper mounting components are there, to have a beeter wiper mountings we should have sufficient space.
The distance 150mm is at the head lamp, to have the sufficient area for the head lamp mounting parts we shoud have minimum gap from the front end of the fender. This how we can calculate the total length of the fender. And there is no specific dimensions or length we need to follow it depend up on car to car. If we are using small cowl mounting parts rather than conventional parts, the 200m becomes lesser value.
Human eye View :
If we have 3 degree angle of flange , when human eye protrude into the engine compartment, he should not see any ugly region inside the engine compartment. And this 3 degree flange surface should restrict the visibility of fasteners.
And the drp area length is inimum 35mm to 40mm to easily have the tool workabilty.
Sill mounting :
Car Plastic screw fasteners for car bumpers & mudguards
Wheel Arc Calculations
Top , side , front ,back views of fender :
Wheel Arc Situation :
After Thicking where the component is ready to manufacture
And the Fender thickness will be 06mmto 0.75mm. And the minimum corner radius of the fender is 2.5mm at all portions. It will help in the case od pedestrian safety and looks good asthetically.
Addition to above points,
Coner Relief for easy part forming 
So,This is how the design conisderations of fender must be taken and similar as my design considerations fenders are designed as per OEM standards.