Week 11 - Final project

Design of Plastic Door Trim Body

Introduction: Door-Trim are the complete plastic solid body which are attached to the developed Body In White (BIW) of the side door and it also holds the aesthetic and safety feature of an automobile. When these features are taken into consideration, the designing of the exterior door trim also faces complexity to produce as one product. Adding more design constraints like providing the required draft angle to the complete model also becomes difficult or sometimes there will be no solutions to create it as one component. Here the ideal solution to address the problem is done by separating the door trim into sub-components by their functions i.e., to hold the window, locking mechanism, bottle holder and map pocket, developed parallel with other components of its kind and then assembled together as one component.

The safety concern of the complete automobile as a product has also become a sensation after the launch of New Car Assessment Programs (NCAP) under the name Bharat New Vehicle Safety Assessment in India in 2017. As it was a factor of concern that has been initially followed worldwide by the developed nations but was reflected at much later time in developing nations such as India. So the plastic material of the door trim must be chosen accordingly keeping the safety of customers in mind.

In the below discussed design model, the following components alone were taken, to develop its solid body using the chosen plastic.

1. Arm-Rest
2. Lower Substrate
3. Map Pocket
4. Map Pocket with Bottle Holder

Material suggestion:

Polybutylene terepthalate (PBT):

good chemical resi9stance and bearing and wear properties.

Acrylonitrile Butadiene Styrene (ABS):

good balance of impact, heat, chemical and abrasion resistance, dimensional stablity, tensile strength, surface hardness, rigidity and electrical characteristics.

Development of Closed Body:

Arm-Rest: This part of the door trim comes in the top portion of the Door, where the passenger/driver near to the door can comfortably rest their hands on it.

Tooling Axis:

Core and Cavity Tooling axis:

When a plastic body is created in a molding, the core is moved with respect to the cavity in a linear path. The joining line of core and cavity is called the tooling axis, The plastic component is poured and ejected respectively to hat axis of the core and cavity motion.For, this above challenge to be satisfied, the discussed tooling axis must be created for the product, keeping the motion of core and cavity in mind. The Draft analysis must be verified with all surfaces of the component cleared with the main tooling axis.

Slider Tooling Axis:

The complete component cannot be cleared in the main tooling axis, hence, a side core must be provided to the mold to make the sides to clear the draft analysis.

Lifter Tooling axis:

Here the Lifter tooling axis is used to show the motion of the slider to create the dog houses.

Steps in Catia to add tooling axis:

1. A visual analysis by us will be undertaken at every axis plane of X,Y and Z to come up with the suitable plane that holds all the features of the surface A.
2. Here the X and Z axis don't suit the above requirement, hence moving to Y-plane we preserve the majority of the details given to surface A.
3. At first we must create a geometrical set, where it should be renamed as the "Tooling axis".
4. To fix the Y axis as the tooling axis, we must construct a line to represent it.
5. For the line creation, we can use the hole present in surface A as the reference and using the point option, we must include a point in the center of the hole.
6. Now to draw a line, using the line-direction command, with the previously created point as the starting end, we must extend it on both sides for a considerable distance, with Y-axis as the direction.
7. Now to comfortably view the final tool axis, we must publish it separately using the publish command in the tools option in CATIA.

Tooling axis snippet:

Following Image shows one side core and one main tooling axis.

Class A Surface:

1. Starting with the Class A as the input, and required output as the plastic component, we should consider the following:
2. The Surface A is the aesthetic part of the given component. Hence, changes made over Class A Surface should be avoided.
3. Draft Angle must be on the Class C Surface.

Steps in Catia to import Class A Surface as neutral file (STP, IGS):

1. Using the open option in the CATIA file menu, the class A Surface file is opened from either IGS, STP or CatPart.
2. If it is in IGS format, the surface A must be joined using distance propagation.

Class A Surface snippet:

Draft Analysis:

When the final component is created, the drafting analysis done to ensure the draft angles are given to the surface C is within the standard range of 3 degrees. By giving this angle, the plastic component is protected from damage while it is ejected. The color order of GBR in the order of Green, Blue or Red.

• if the draft shows green color, then the draft angle is clearing the 3 degree angle.
• If the blue color is highlighted, then the draft is somewhere between 0 and 3. This area must be studied to make its value close to the 3 degree clearance.
• if the red color is highlighted, then the draft is below 0 degree, this color separates the core from the cavity or slider.

Draft Analysis to the engineering feature, must also be checked.

Here, the dog house is the only feature that is made, so the outer draft of 1.5 degree and inner draft of 0.5 degree, should also be studied by changing the green value and the tooling axis with slider axis at necessary positions respectively.

Steps in Catia to Drafting Analysis:

1. Add material using the view option to let the draft analysis to run.
2. Select the surface or final part body to make it highlighted in the feature tree.
3. Use the analysis in the insert option in the CATIA's menu bar, to find the Feature draft analysis.
4. Now after selecting the option, two pop window will be displayed, where:
5. One has the color coding, where we must define the colors in the order of GBR (Green, Blue, Red) respectively and set the angle value to be 2.9 for Green, 0 for Blue, and less than 0 as Red.
6. Another pop up has several tools for draft analysis. Now from the right most corner of the screen, drag the direction compass and place it on the tooling axis, where the resulting compass aligns with the tooling axis. Now after it gets aligned, lock the compass position using the Compass Lock tool.
7. To view the draft analysis, select the Surface or final closed body. By choosing it as mentioned, the analysis produces the color coding over the parts where the draft condition/angle satisfies as we mentioned.

Draft Analysis - Class A Surface snippet:

Main Tooling Axis:

Side-core Tooling Axis:

Draft Analysis - Closed Body clearing by Class A Side snippet:

Drafting Analysis - Closed Body with Engineering Features clearing by side core tooling axis snippet @ 0.5:

Class B Surface:

The Class B surface is the other side of the Class A surface of the plastic component and where the portion sits on the core.

Make Class B as the sacrificing portion of the component at the core, we ensure the ejector pins motion to push the finished component out of the mold to fall on Class B, again saving Class A from the stress from ejector pins.

Steps in Catia to Create Class B Surface:

1. From the given master section by using the measure tool, the thickness of the given model is identified as 2.5mm.
2. Now use the offset option to offset the Class A Surface.
3. There are some places where the offset fails to add the surface.
4. Use the sweep command with reference surface, by selecting the profile and guide curve, to recreate the surface lost.
5. Now use the join command, to join the surface created.
6. Now the Class B surface is created successfully.

Class B Surface snippet:

Class C Surface:

1. The Class C surface is in between portions of Class A and Class B, where the volume is added or in other words, plastic thickness is given here.
2. The Class C Surface is given the draft angle of 3.
3. To make the component to be easily ejected from the mold, it requires a 3 degree draft angle.

Steps in Catia to create Class C Surface:

1. Use the Class A surface as the reference and extract the boundaries individually on every side where the curvature changes using boundary tool with tangent continuity.
2. Now use the "swept tool" and "with draft directions" to extrude the boundaries and tooling axis as the guidelines and with a draft angle as 3 degrees in outward direction.
3. Now use the extrapolate tool to intersect the swept extrudes by selecting the intersection edges of the swept extrudes to intersect with adjacent swept extrudes.
4. Use the trim to join the swept surfaces.
5. Save it in a separate geometrical set.

Class C Surface Snippet:

Final Trim:

1. The resulting surface being formed after joining the Class A, B and C as per the above spoken features specific to the surfaces respectively is done in Final trim.
2. This showcases the cavity and core's design of how the mold should be created.

Steps in Catia to create joined Class A, B and C Surface (closed):

1. Use the join command to join the Class C surfaces of boundary and hole swept extrudes with Class A.
2. Use the trim command to trim the extended edges of the class C with Class B.

Final Trim Snippet:

Solid Body:

Solid body is the part body created after calling the closed surface command on the Final trim surface.

Steps in Catia to create Closed part body:

1. Use the closed body tool in part design to create the part body.
2. Run Draft analysis using feature draft analysis from tools, and selecting the part.

Solid Body Snippet:

Lower Substrate: This part of the door trim comes in the middle portion of the Door, where other components are placed over it using heat stakes.

Tooling Axis:

Core and Cavity Tooling axis:

When a plastic body is created in a molding, the core is moved with respect to the cavity in a linear path. The joining line of core and cavity is called the tooling axis, The plastic component is poured and ejected respectively to hat axis of the core and cavity motion.For, this above challenge to be satisfied, the discussed tooling axis must be created for the product, keeping the motion of core and cavity in mind. The Draft analysis must be verified with all surfaces of the component cleared with the main tooling axis.

Lifter Tooling axis:

Here the Lifter tooling axis is used to show the motion of the slider to create the dog houses.

Steps in Catia to add tooling axis:

1. A visual analysis by us will be undertaken at every axis plane of X,Y and Z to come up with the suitable plane that holds all the features of the surface A.
2. Here the X and Z axis don't suit the above requirement, hence moving to X-plane we preserve the majority of the details given to surface A.
3. At first we must create a geometrical set, where it should be renamed as the "Tooling axis".
4. To fix the X axis as the tooling axis, we must construct a line to represent it.
5. For the line creation, we can use the hole present in surface A as the reference and using the point option, we must include a point in the center of the hole.
6. Now to draw a line, using the line-direction command, with the previously created point as the starting end, we must extend it on both sides for a considerable distance, with X-axis as the direction.
7. Now to comfortably view the final tool axis, we must publish it separately using the publish command in the tools option in CATIA.

Tooling axis snippet:

Class A Surface:

1. Starting with the Class A as the input, and required output as the plastic component, we should consider the following:
2. The Surface A is the aesthetic part of the given component. Hence, changes made over Class A Surface should be avoided.
3. Draft Angle must be on the Class C Surface.

Steps in Catia to import Class A Surface as neutral file (STP, IGS):

1. Using the open option in the CATIA file menu, the class A Surface file is opened from either IGS, STP or CatPart.
2. If it is in IGS format, the surface A must be joined using distance propagation.

Class A Surface snippet:

Draft Analysis:

When the final component is created, the drafting analysis done to ensure the draft angles are given to the surface C is within the standard range of 3 degrees. By giving this angle, the plastic component is protected from damage while it is ejected. The color order of GBR in the order of Green, Blue or Red.

• if the draft shows green color, then the draft angle is clearing the 3 degree angle.
• If the blue color is highlighted, then the draft is somewhere between 0 and 3. This area must be studied to make its value close to the 3 degree clearance.
• if the red color is highlighted, then the draft is below 0 degree, this color separates the core from the cavity or slider.

Draft Analysis to the engineering feature, must also be checked.

Here, the dog house is the only feature that is made, so the outer draft of 1.5 degree and inner draft of 0.5 degree, should also be studied by changing the green value and the tooling axis with slider axis at necessary positions respectively.

Steps in Catia to Drafting Analysis:

1. Add material using the view option to let the draft analysis to run.
2. Select the surface or final part body to make it highlighted in the feature tree.
3. Use the analysis in the insert option in the CATIA's menu bar, to find the Feature draft analysis.
4. Now after selecting the option, two pop window will be displayed, where:
5. One has the color coding, where we must define the colors in the order of GBR (Green, Blue, Red) respectively and set the angle value to be 2.9 for Green, 0 for Blue, and less than 0 as Red.
6. Another pop up has several tools for draft analysis. Now from the right most corner of the screen, drag the direction compass and place it on the tooling axis, where the resulting compass aligns with the tooling axis. Now after it gets aligned, lock the compass position using the Compass Lock tool.
7. To view the draft analysis, select the Surface or final closed body. By choosing it as mentioned, the analysis produces the color coding over the parts where the draft condition/angle satisfies as we mentioned.

Draft Analysis - Class A Surface snippet:

Draft Analysis - Closed Body clearing by Class A Side snippet:

Drafting Analysis - Closed Body with Engineering Features clearing by tooling axis snippet:

Drafting Analysis - Closed Body with Engineering features clearing by Lifter axis snippet:

Class B Surface:

The Class B surface is the other side of the Class A surface of the plastic component and where the portion sits on the core.

Make Class B as the sacrificing portion of the component at the core, we ensure the ejector pins motion to push the finished component out of the mold to fall on Class B, again saving Class A from the stress from ejector pins.

Steps in Catia to Create Class B Surface:

1. From the given master section by using the measure tool, the thickness of the given model is identified as 2.5mm.
2. Now use the offset option to offset the Class A Surface.
3. There are some places where the offset fails to add the surface.
4. Use the sweep command with reference surface, by selecting the profile and guide curve, to recreate the surface lost.
5. Now use the join command, to join the surface created.
6. Now the Class B surface is created successfully.

Class B Surface snippet:

Class C Surface:

1. The Class C surface is in between portions of Class A and Class B, where the volume is added or in other words, plastic thickness is given here.
2. The Class C Surface is given the draft angle of 3.
3. To make the component to be easily ejected from the mold, it requires a 3 degree draft angle.

Steps in Catia to create Class C Surface:

1. Use the Class A surface as the reference and extract the boundaries individually on every side where the curvature changes using boundary tool with tangent continuity.
2. Now use the "swept tool" and "with draft directions" to extrude the boundaries and tooling axis as the guidelines and with a draft angle as 3 degrees in outward direction.
3. Now use the extrapolate tool to intersect the swept extrudes by selecting the intersection edges of the swept extrudes to intersect with adjacent swept extrudes.
4. Use the trim to join the swept surfaces.
5. Save it in a separate geometrical set.

Class C Surface Snippet:

Final Trim:

1. The resulting surface being formed after joining the Class A, B and C as per the above spoken features specific to the surfaces respectively is done in Final trim.
2. This showcases the cavity and core's design of how the mold should be created.

Steps in Catia to create joined Class A, B and C Surface (closed):

1. Use the join command to join the Class C surfaces of boundary and hole swept extrudes with Class A.
2. Use the trim command to trim the extended edges of the class C with Class B.

Final Trim Snippet:

Solid Body:

Solid body is the part body created after calling the closed surface command on the Final trim surface.

Steps in Catia to create Closed part body:

1. Use the closed body tool in part design to create the part body.
2. Run Draft analysis using feature draft analysis from tools, and selecting the part.

Solid Body Snippet:

Map Pocket: This part of the door trim comes in the middle portion of the Door, where the passenger/driver near to the door can keep notebooks and other important files.

Tooling Axis:

Core and Cavity Tooling axis:

When a plastic body is created in a molding, the core is moved with respect to the cavity in a linear path. The joining line of core and cavity is called the tooling axis, The plastic component is poured and ejected respectively to hat axis of the core and cavity motion.For, this above challenge to be satisfied, the discussed tooling axis must be created for the product, keeping the motion of core and cavity in mind. The Draft analysis must be verified with all surfaces of the component cleared with the main tooling axis.

Slider Tooling Axis:

The complete component cannot be cleared in the main tooling axis, hence, a side core must be provided to the mold to make the sides to clear the draft analysis.

Lifter Tooling axis:

Here the Lifter tooling axis is used to show the motion of the slider to create the dog houses.

Steps in Catia to add tooling axis:

1. A visual analysis by us will be undertaken at every axis plane of X,Y and Z to come up with the suitable plane that holds all the features of the surface A.
2. Here the X and Z axis don't suit the above requirement, hence moving to Y-plane we preserve the majority of the details given to surface A.
3. At first we must create a geometrical set, where it should be renamed as the "Tooling axis".
4. To fix the Y axis as the tooling axis, we must construct a line to represent it.
5. For the line creation, we can use the hole present in surface A as the reference and using the point option, we must include a point in the center of the hole.
6. Now to draw a line, using the line-direction command, with the previously created point as the starting end, we must extend it on both sides for a considerable distance, with Y-axis as the direction.
7. Now to comfortably view the final tool axis, we must publish it separately using the publish command in the tools option in CATIA.

Tooling axis snippet:

Class A Surface:

1. Starting with the Class A as the input, and required output as the plastic component, we should consider the following:
2. The Surface A is the aesthetic part of the given component. Hence, changes made over Class A Surface should be avoided.
3. Draft Angle must be on the Class C Surface.

Steps in Catia to import Class A Surface as neutral file (STP, IGS):

1. Using the open option in the CATIA file menu, the class A Surface file is opened from either IGS, STP or CatPart.
2. If it is in IGS format, the surface A must be joined using distance propagation.

Class A Surface snippet:

Draft Analysis:

When the final component is created, the drafting analysis done to ensure the draft angles are given to the surface C is within the standard range of 3 degrees. By giving this angle, the plastic component is protected from damage while it is ejected. The color order of GBR in the order of Green, Blue or Red.

• if the draft shows green color, then the draft angle is clearing the 3 degree angle.
• If the blue color is highlighted, then the draft is somewhere between 0 and 3. This area must be studied to make its value close to the 3 degree clearance.
• if the red color is highlighted, then the draft is below 0 degree, this color separates the core from the cavity or slider.

Draft Analysis to the engineering feature, must also be checked.

Here, the dog house is the only feature that is made, so the outer draft of 1.5 degree and inner draft of 0.5 degree, should also be studied by changing the green value and the tooling axis with slider axis at necessary positions respectively.

Steps in Catia to Drafting Analysis:

1. Add material using the view option to let the draft analysis to run.
2. Select the surface or final part body to make it highlighted in the feature tree.
3. Use the analysis in the insert option in the CATIA's menu bar, to find the Feature draft analysis.
4. Now after selecting the option, two pop window will be displayed, where:
5. One has the color coding, where we must define the colors in the order of GBR (Green, Blue, Red) respectively and set the angle value to be 2.9 for Green, 0 for Blue, and less than 0 as Red.
6. Another pop up has several tools for draft analysis. Now from the right most corner of the screen, drag the direction compass and place it on the tooling axis, where the resulting compass aligns with the tooling axis. Now after it gets aligned, lock the compass position using the Compass Lock tool.
7. To view the draft analysis, select the Surface or final closed body. By choosing it as mentioned, the analysis produces the color coding over the parts where the draft condition/angle satisfies as we mentioned.

Draft Analysis - Class A Surface snippet:

Draft Analysis - Closed Body clearing by Class A Side snippet:

Draft Analysis - Closed Body clearing by Class B Side snippet @ 0.5 Draft Angle:

Drafting Analysis - Closed Body with Engineering features clearing by Lifter axis snippet:

Class B Surface:

The Class B surface is the other side of the Class A surface of the plastic component and where the portion sits on the core.

Make Class B as the sacrificing portion of the component at the core, we ensure the ejector pins motion to push the finished component out of the mold to fall on Class B, again saving Class A from the stress from ejector pins.

Steps in Catia to Create Class B Surface:

1. From the given master section by using the measure tool, the thickness of the given model is identified as 2.5mm.
2. Now use the offset option to offset the Class A Surface.
3. There are some places where the offset fails to add the surface.
4. Use the sweep command with reference surface, by selecting the profile and guide curve, to recreate the surface lost.
5. Now use the join command, to join the surface created.
6. Now the Class B surface is created successfully.

Class B Surface snippet:

Class C Surface:

1. The Class C surface is in between portions of Class A and Class B, where the volume is added or in other words, plastic thickness is given here.
2. The Class C Surface is given the draft angle of 3.
3. To make the component to be easily ejected from the mold, it requires a 3 degree draft angle.

Steps in Catia to create Class C Surface:

1. Use the Class A surface as the reference and extract the boundaries individually on every side where the curvature changes using boundary tool with tangent continuity.
2. Now use the "swept tool" and "with draft directions" to extrude the boundaries and tooling axis as the guidelines and with a draft angle as 3 degrees in outward direction.
3. Now use the extrapolate tool to intersect the swept extrudes by selecting the intersection edges of the swept extrudes to intersect with adjacent swept extrudes.
4. Use the trim to join the swept surfaces.
5. Save it in a separate geometrical set.

Class C Surface Snippet:

Final Trim:

1. The resulting surface being formed after joining the Class A, B and C as per the above spoken features specific to the surfaces respectively is done in Final trim.
2. This showcases the cavity and core's design of how the mold should be created.

Steps in Catia to create joined Class A, B and C Surface (closed):

1. Use the join command to join the Class C surfaces of boundary and hole swept extrudes with Class A.
2. Use the trim command to trim the extended edges of the class C with Class B.

Final Trim Snippet:

Solid Body:

Solid body is the part body created after calling the closed surface command on the Final trim surface.

Steps in Catia to create Closed part body:

1. Use the closed body tool in part design to create the part body.
2. Run Draft analysis using feature draft analysis from tools, and selecting the part.

Solid Body Snippet:

Map Pocket with Bottle Holder: This part of the door trim comes in the middle portion of the Door, where the passenger/driver near to the door can keep their bottle or flask.

Tooling Axis:

Core and Cavity Tooling axis:

When a plastic body is created in a molding, the core is moved with respect to the cavity in a linear path. The joining line of core and cavity is called the tooling axis, The plastic component is poured and ejected respectively to hat axis of the core and cavity motion.For, this above challenge to be satisfied, the discussed tooling axis must be created for the product, keeping the motion of core and cavity in mind. The Draft analysis must be verified with all surfaces of the component cleared with the main tooling axis.

Slider Tooling Axis:

The complete component cannot be cleared in the main tooling axis, hence, a side core must be provided to the mold to make the sides to clear the draft analysis.

Lifter Tooling axis:

Here the Lifter tooling axis is used to show the motion of the slider to create the dog houses.

Steps in Catia to add tooling axis:

1. A visual analysis by us will be undertaken at every axis plane of X,Y and Z to come up with the suitable plane that holds all the features of the surface A.
2. Here the X and Z axis don't suit the above requirement, hence moving to Y-plane we preserve the majority of the details given to surface A.
3. At first we must create a geometrical set, where it should be renamed as the "Tooling axis".
4. To fix the Y axis as the tooling axis, we must construct a line to represent it.
5. For the line creation, we can use the hole present in surface A as the reference and using the point option, we must include a point in the center of the hole.
6. Now to draw a line, using the line-direction command, with the previously created point as the starting end, we must extend it on both sides for a considerable distance, with Y-axis as the direction.
7. Now to comfortably view the final tool axis, we must publish it separately using the publish command in the tools option in CATIA.

Tooling axis snippet:

Class A Surface:

1. Starting with the Class A as the input, and required output as the plastic component, we should consider the following:
2. The Surface A is the aesthetic part of the given component. Hence, changes made over Class A Surface should be avoided.
3. Draft Angle must be on the Class C Surface.

Steps in Catia to import Class A Surface as neutral file (STP, IGS):

1. Using the open option in the CATIA file menu, the class A Surface file is opened from either IGS, STP or CatPart.
2. If it is in IGS format, the surface A must be joined using distance propagation.

Class A Surface snippet:

Draft Analysis:

When the final component is created, the drafting analysis done to ensure the draft angles are given to the surface C is within the standard range of 3 degrees. By giving this angle, the plastic component is protected from damage while it is ejected. The color order of GBR in the order of Green, Blue or Red.

• if the draft shows green color, then the draft angle is clearing the 3 degree angle.
• If the blue color is highlighted, then the draft is somewhere between 0 and 3. This area must be studied to make its value close to the 3 degree clearance.
• if the red color is highlighted, then the draft is below 0 degree, this color separates the core from the cavity or slider.

Draft Analysis to the engineering feature, must also be checked.

Here, the dog house is the only feature that is made, so the outer draft of 1.5 degree and inner draft of 0.5 degree, should also be studied by changing the green value and the tooling axis with slider axis at necessary positions respectively.

Steps in Catia to Drafting Analysis:

1. Add material using the view option to let the draft analysis to run.
2. Select the surface or final part body to make it highlighted in the feature tree.
3. Use the analysis in the insert option in the CATIA's menu bar, to find the Feature draft analysis.
4. Now after selecting the option, two pop window will be displayed, where:
5. One has the color coding, where we must define the colors in the order of GBR (Green, Blue, Red) respectively and set the angle value to be 2.9 for Green, 0 for Blue, and less than 0 as Red.
6. Other pop up has several tools for draft analysis. Now from the right most corner of the screen, drag the direction compass and place it on the tooling axis, where the resulting compass aligns with the tooling axis. Now after it gets aligned, lock the compass position using the Compass Lock tool.
7. To view the draft analysis, select the Surface or final closed body. By choosing it as mentioned, the analysis produces the color coding over the parts where the draft condition/angle satisfies as we mentioned.

Draft Analysis - Class A Surface snippet:

The Blue regions are measured in Class A have draft angle 0, it can be cleared along in Main tooling Axis.

Draft Analysis - Closed Body clearing by Class A Side snippet:

Drafting Analysis - Closed Body with Engineering Features clearing by tooling axis snippet:

Class B Surface:

The Class B surface is the other side of the Class A surface of the plastic component and where the portion sits on the core.

Make Class B as the sacrificing portion of the component at the core, we ensure the ejector pins motion to push the finished component out of the mold to fall on Class B, again saving Class A from the stress from ejector pins.

Steps in Catia to Create Class B Surface:

1. From the given master section by using the measure tool, the thickness of the given model is identified as 2.5mm.
2. Now use the offset option to offset the Class A Surface.
3. There are some places where the offset fails to add the surface.
4. Use the sweep command with reference surface, by sellecting the profile and guide curvce, to recreate the surface lost.
5. Now use the join command, to join the surface created.
6. Now the Class B surface is created successfully.

Class B Surface snippet:

Class C Surface:

1. The Class C surface is in between portions of Class A and Class B, where the volume is added or in other words, plastic thickness is given here.
2. The Class C Surface is given the draft angle of 3.
3. To make the component to be easily ejected from the mold, it requires a 3 degree draft angle.

Steps in Catia to create Class C Surface:

1. Use the Class A surface as the reference and extract the boundaries individually on every side where the curvature changes using boundary tool with tangent continuity.
2. Now use the "swept tool" and "with draft directions" to extrude the boundaries and tooling axis as the guidelines and with a draft angle as 3 degrees in outward direction.
3. Now use the extrapolate tool to intersect the swept extrudes by selecting the intersection edges of the swept extrudes to intersect with adjacent swept extrudes.
4. Use the trim to join the swept surfaces.
5. Save it in a separate geometrical set.

Class C Surface Snippet:

Final Trim:

1. The resulting surface being formed after joining the Class A, B and C as per the above spoken features specific to the surfaces respectively is done in Final trim.
2. This showcases the cavity and core's design of how the mold should be created.

Steps in Catia to create joined Class A, B and C Surface (closed):

1. Use the join command to join the Class C surfaces of boundary and hole swept extrudes with Class A.
2. Use the trim command to trim the extended edges of the class C with Class B.

Final Trim Snippet:

Solid Body:

Solid body is the part body created after calling the closed surface command on the Final trim surface.

Steps in Catia to create Closed part body:

1. Use the closed body tool in part design to create the part body.
2. Run Draft analysis using feature draft analysis from tools, and selecting the part.

Solid Body Snippet:

Final Assembly:

As the given design followed Bottom-Up approach, the part creation are done where they are assembled, hence there is no relation given to the part.

Final Assembly Output:

Mastersection: Along with the input class A surface, the master section is given. The purpose of the master section is to design the feature by carry-over study.

Re-Mastering: A Dumb Solid is given as a reference same as the Master-section, where the feature needed to developed based on the dimensions. Below a snap of the developed part coinciding with the dump solid is shown. And from this the Dog House is kept in Door trim places where the part is placed over BIW.

Rendered Final Assembly:

Note:

The Flanges given in Master-Section are created with 90 degree of draft in Class C Surface, but in the creation of the door trim, the draft angle considered was 3 degree inwwards, hence the extended angle can create blue area in flange.

There are places where flange are needed, hence in those areas design were given on own.