Rough styling came first: we built the internal structure and took it through to production tooling

The situation when the request came in

The client was replacing an existing model, and came to us once the concept and the rough styling of the next model were finished. Because the exterior was already fixed, the internal structure had to work within that constraint. On top of that, a weight target and a cost target had both been set, so the internal structure had to satisfy styling, weight and cost at the same time.

What we did

Treating the rough styling as a fixed constraint, we worked out the internal structure from scratch. We put together an arrangement that could reach both the weight target and the cost target, and confirmed strength with static analysis alongside it. In parallel with the design we ran the selection of the volume manufacturer, and handled the tooling order as part of the same engagement.

The outcome

For the structural parts in our scope, both the weight target and the cost target were met. Outside our scope, the cost of a major drive component came in well over its target, so the product as a whole did not reach its cost target. Work towards volume production is ongoing.

What this project shows

When the styling is fixed first, the freedom left in the internal structure is heavily restricted. Under that condition, the way to hit weight and cost together is not to settle them after the structure is frozen, but to sketch the internal structure in parallel with the styling being finalised.