Scene 1 (0s)
DOOR TRIM ENGINEERING Complete Design & Development Lifecycle for Automotive Interior Systems MECHANICAL DESIGN TOOLING MANUFACTURING.
Scene 2 (7s)
Key Components Main Substrate: The primary structural carrier. Trim Inserts: Upper and Center decorative panels. Functional Parts: Pull handle, Armrest, Map Pocket. Speaker Grille: Lower trim integration. Quadrant Cover: Mirror mounting interface. SYSTEM ARCHITECTURE OVERVIEW.
Scene 3 (19s)
Class A Strategy Visible aesthetics, graining definition, and gap/flush targets based on styling intent. Engineering B/C Creation of Class B (offset) and Class C (closing) surfaces to build engineering thickness. Section Planning Definition of seal interfaces, glass run channels, and flange connectivity for assembly. MASTER SECTIONS & SURFACES.
Scene 4 (33s)
Component Material Type Density (g/cm³) Surface Finish Lower Substrate PP 20% Talc 1.05 Technical Graining Upper Trim ABS / PCABS 1.08 Soft Touch Paint / Flocking Armrest PU Foam + PVC/Leather - Stitched Wrap Fasteners POM / PA66 1.41 Natural / Self-Lubricating MATERIAL SPECIFICATIONS.
Scene 5 (44s)
Draft Angles: Minimum 0.5° for smooth release; 3.0° for grained surfaces. Wall Thickness: Standard 2.5mm to 3.0mm to optimize cycle time vs. strength. Rib Design: Width should be 4060% of main wall to prevent sink marks. INJECTION MOLDING DESIGN RULES.
Scene 6 (58s)
ATTACHMENT STRATEGY BSide Engineering Doghouses: Tooling axis correction for clip placement. Heat Stakes: Thermal permanent bonding for sub-assemblies. Screw Bosses: M5/M6 tapping points for structural mounting. Locators: 2-way and 4-way pin constraints for YZ control..
Scene 7 (1m 11s)
Primary Carrier Loading the main substrate and installing wiring harnesses. Sub-Assemblies Heat staking armrest and map pocket to the carrier. ASurface Finishes Snapping in switches, pull handles, and decorative inserts. Vehicle Fitment Final clip engagement to BIW door inner panel. COMPLETE ASSEMBLY SEQUENCE.
Scene 8 (1m 24s)
Failure Mode: BSR Buzz, Squeak, and Rattle due to loose clip fitment or friction at part interfaces. Material Fatigue Stress whitening or cracking at screw bosses under high torque/vibration. Warpage Dimensional instability in high heat environments Desert testing). DFMEA & RISK MANAGEMENT.
Scene 9 (1m 37s)
Perceived Quality Targets Nominal Gap: Target 0.5mm - 1.0mm between inserts. Flushness: Step height control within 0.5mm. Anti-Rattle: Use of flocking tape EPE/PET) at sliding contact areas. GAP & FLUSH / PERCEPTION.
Scene 10 (1m 49s)
Structured hierarchical BOM ensures traceability for PLM systems and purchasing teams. + DOOR_TRIM_ASSY_LH + SUBSTRATE_GROUP (Lower, Carrier) - SUBSTRATE_LOWER_PART (BOM-ID: 1024) + DECOR_GROUP (Upper, Bolster) + HARDWARE_GROUP (Clips, Screws) + ELECTRONICS (Switch Bezel, LED) CATIA PRODUCT TREE & BOM.
Scene 11 (2m 1s)
MANUFACTURING COSTING FACTORS.
Scene 12 (2m 6s)
Standard process followed by Tata, Mahindra, and VW for interior programs. Concept G1G2 Styling freeze, benchmarking, and feasibility studies. Design G3G4 Master section release, Class A design, and CAD data freeze. Tooling G5G6 Mold manufacturing, T0/T1 samples, and graining freeze. Validation & SOP DV/PV testing, line trials, and Start of Production. GATED DEVELOPMENT LIFECYCLE.
Scene 13 (2m 22s)
Q&A Thank you for your attention to engineering detail..
Scene 14 (2m 29s)
I IMAGE SOURCES https://imgv2-2-f.scribdassets.com/img/document/525278405/original/1f16832fed/1?v=1 Source: www.scribd.com https://skl-sklc-tinymce-2021.s3.amazonaws.com/comp/2022/04/tec_027_08_1650950479.gif Source: skill-lync.com https://mg-techworks.com/assets/images/gap-and-flush-automotive-interior-design-Bb6HADmJ.webp •Thumbnail for mg- Source: mg-techworks.com techworks.com.