Automotive Design & Manufacturing Intensive

Describe the injection molding cycle and the function of key mold components (core, cavity, runners, gates).

Compare key automotive thermoplastics (PP, ABS, PC/ABS, PA6) based on mechanical, thermal, and chemical properties.

Identify common injection molding defects (weld lines, short shots, warpage, sink marks) and their root causes.

Apply golden rules for part design, including draft angles for textured surfaces and rib-to-wall thickness ratios.

Select an appropriate gate type and location for a given automotive part geometry.

Define datums and establish a datum reference frame (A-B-C) for a simple part.

Interpret and apply position tolerance to a feature pattern and profile of a surface tolerance to a curved feature.

Describe how a 2D drawing with GD&T callouts is created and how design data is structured in a PLM system.

Justify material selection for an automotive grab handle based on functional and manufacturing requirements.

Develop the modeling sequence for a grab handle incorporating a cantilever snap-fit and a screw boss using CATIA Part Design logic.

Apply appropriate wall thickness, draft angles, and fillet radii to the grab handle based on injection molding design rules.

Perform a DFM review on the grab handle, identifying moldability issues related to the base part and attachment features.

Conduct a DFMEA on the grab handle, identifying potential failure modes related to molding, assembly, and in-service use.

Produce a 2D drawing of the grab handle with a complete datum scheme and GD&T callouts for critical features.

Describe the ECO/ECR workflow and the roles involved in approving an engineering change in an automotive context.

Interpret an ECO document to identify its scope, rationale, and affected components in an interior trim assembly.

Evaluate surface quality requirements for visible interior trim panels using CATIA GSD logic.

Evaluate the DFM and tooling impact of the ECO on the injection-molded assembly.

Analyze the DFA impact of the ECO on the assembly sequence and joining methods.

Update the DFMEA to reflect design changes introduced by the ECO.

Produce updated 2D drawings with revised GD&T and document changes in a PLM-style format.

Describe the sheet metal stamping process stages (blanking, drawing, trimming, flanging) and their sequence.

Compare common automotive sheet metals (mild steel, HSLA, DP steel, aluminum) based on strength and formability.

Identify common stamping defects (springback, wrinkling, tearing) and explain how process controls mitigate them.

Apply golden rules for sheet metal design, including bend radii for high-strength steel, hole-to-edge distance, and minimum flange length.

Calculate a flat pattern from a 3D model using K-factor and bend allowance principles.

Describe the five phases of APQP and how phase gates connect to design reviews and validation builds.

Explain where DFM, DFMEA, and GD&T deliverables fit within the APQP timeline.

Justify material and gauge selection for a mounting bracket based on load requirements and formability.

Develop the modeling sequence for a mounting bracket using CATIA Part Design and Sheet Metal workbench logic.

Apply appropriate bend radii, relief cuts, and flange dimensions to the bracket design.

Perform a DFM review on the bracket for stamping feasibility, identifying risks like springback and tearing.

Identify the top failure modes in a DFMEA for the bracket, focusing on stamping and assembly risks.

Define a GD&T scheme by establishing datums and applying position and profile tolerances to critical features.

Produce a complete 2D drawing of the bracket including all views, dimensions, GD&T, and a flat pattern view.

Interpret an ECO requiring modification to a multi-part Body-in-White (BIW) structural bracket assembly.

Model a multi-part sheet metal assembly in CATIA including spot weld flanges and joint features.

Analyze the ECO's impact on material utilization by comparing original and revised flat patterns.

Perform a DFA review to assess the ECO's impact on assembly sequence and joining methods (e.g., spot welding access).

Identify potential stamping die modifications or risks resulting from the ECO.

Update the DFMEA to reflect the design changes from the ECO.

Create a Design Verification Plan (DVP&R) using APQP principles informed by the updated DFMEA.

Produce updated 2D drawings with revised GD&T and document the ECO in a PLM-style change notice.