Automotive Design Feasibility
Injection moulding production-ready parts
Ensuring air intake system components were feasible for injection moulding while adapting to evolving vehicle development.
A new 4×4 vehicle required a fully manufacturable air intake system, including ducts, air cleaners, and related components.
The client provided prototype designs but needed a partner to refine them for production while ensuring proper packaging within the vehicle. As the vehicle’s development progressed, the designs had to remain flexible and responsive to changes.
Approach
Applying Generative Parametrics DNA Modelling.
The prototype parts were mapped into the DNA modelling framework, a methodology that automatically generates and updates manufacturing-feasible designs in response to any changes. This ensured that as the vehicle evolved, the air intake system remained optimised for production without delaying development timelines.
Maximising Efficiency
Designing for injection moulding requires balancing structural integrity, manufacturability, and cost. The methodology delivered:
- Manufacturing feasibility – ensuring all components could be efficiently injection moulded.
- Optimised packaging – integrating seamlessly within the evolving vehicle structure.
- Cost efficiencies – reducing complexity and minimising tooling expenses.
- Speed and flexibility – enabling rapid design updates in response to vehicle modifications.
The Outcome
Seamless integration with an evolving vehicle platform.
By leveraging advanced generative design, the air induction system components were transformed into fully manufacturable designs. The flexible modelling approach allowed for quick adaptation to ongoing vehicle changes, ensuring production feasibility without disruptions to the overall program.
