Introduction to Automotive Product Design

Introduction to Automotive Product Design

Design is a core part of innovation. It doesn't just shape how products look—it determines how they function, how they’re made, and how they meet customer needs. Especially in fields like automotive and mechanical engineering, plastic product design is central to creating reliable, efficient, and appealing products.

This blog breaks down the entire journey of product design—from idea to market—highlighting key steps, tools, and roles involved.

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 Table of Contents

• Automotive Product Design Process

• Role of a Product Design Engineer

• Choosing Your Design Domain

• Conclusion

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Automotive Product Design Process

Designing automotive parts—especially plastic interiors and BIW structures—involves multiple stages:

• Idea Generation

  • Based on customer needs or company capabilities

  • Market research filters feasible ideas

• Design Process Planning

  • Define → Design → Develop → Test → Release

• Concept Finalization and Clay Modeling

  • Clay models are built to visualize and refine aesthetics

  • Scanned using 3D scanners to create point cloud data

• CAD Modeling and Surfacing

  • Convert 3D scan into A-Surface (styling surface)

  • Add thickness and features for manufacturability

  • Ensure compatibility with surrounding parts

• Simulation and Analysis

  • Safety and crash analysis

  • Manufacturing feasibility simulation

  • Changes are iteratively applied based on results

• Prototyping and Testing

  • Functional physical prototypes are built

  • Test for assembly, performance, material quality

• Tool Creation and Manufacturing

  • Final part designs are used to create molds or tools

  • Multiple validations are required before CNC machining

• Final Assembly and Quality Checks

  • Assembled at factory stations

  • Tested for waterproofing, noise, structure, engine performance

• Marketing and Sales

  • Product launches are supported by strategic marketing

  • Cars are sold in showrooms after final approval

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Role of a Automotive Product Design Engineer

A design engineer is not just someone who converts 2D to 3D. Their responsibilities include:

• Surface feasibility checks: Can the design be manufactured?

• CAD modeling: Creating solid models with features

• Benchmarking: Study competitor models for internal layout and reinforcements

• Manufacturing drawing creation

• DFM/DFA: Design for manufacturing, assembly, safety, serviceability

• Tooling feasibility check

• CAE communication: Understand feedback from simulation teams

• Compliance knowledge: FMVSS, CMVSS, Euro NCAP standards

• GD&T and stack-up tolerance analysis

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Choosing Your Design Domain

Ask yourself:

• Do I prefer plastics, metals, or hybrid materials?

• Am I interested in part design, tool design, or full product lifecycle?

• Do I enjoy simulations or hands-on manufacturing planning?

You can specialize in:

• Plastic Product Design

• BIW (Body-in-White) Design

• Special Purpose Machine Design

• Tool and Fixture Design

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Conclusion

Plastic product design is at the intersection of creativity, functionality, and engineering precision. It takes a deep understanding of design principles, materials, simulation tools, and manufacturing processes.

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