Week 11 - Final project

Aim: Development of a Door Trim panel

Intent: To create thickened plastic components using the class A surface of the following door trim panel.

Objective:

To create a thickened component with nominal thickness using class A.

To create B surface features using the master section reference

Door trim panel:

An automobile door is a complex module, which consists of various fixed and movable subassemblies and components. Parameters such as safety, vehicle dynamics, aesthetics, and strength are critical while designing the door assembly. Apart from the above, the design of door trim should minimize BSR (buzz squeak and rattle) in vehicle running conditions. Stiffness is one of the key engineering requirements which if not optimized will result in higher BSR levels and failure of the door trim components.

Class A

In automotive design, a class A surface is any of a set of freeform surfaces of high efficiency and quality. Although strictly, it is nothing more than saying the surfaces have curvature and tangency alignment – to ideal aesthetical reflection quality, many people interpret class A surfaces to have G2 (or even G3) curvature continuity to one another.

lower substrate

Map pocket

Armrest

master section:

Master sections are the guides for design requirements that decide the component packaging after technical (Styling, Concept, or Class-A) surfaces.

B side features & flanges created using master section references

Class B: The Class B finish is a quality finish with only minimal imperfections. A Class B finish is the most common finish for exterior surfaces. It is normally specified on surfaces such as external covers, panels, and parts that are fairly prominent.

Class C: The Class C finish allows more imperfections than Class A or B. Class C is often specified for interior surfaces not readily visible, surfaces that will be covered by another part when assembled, or surfaces that the Customer feels do not need to meet a high cosmetic finish. This Class is generally used for parts or surfaces which are not viewed after installation or viewed only for service.

Class B surface features:

Heat stakes

Ribs

Push pins

screw bosses

Doghouse

4-way locator

Final door trim: