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Design & Engineering

With over 20 years' experience covering the complete spectrum of engineering applications, we are experts in vehicle development. It is therefore essential for us to keep an eye not only on the big picture, but also on the all-important details. From concept development to series launch support of individual parts and modules and the development of complete vehicles - we combine expert knowledge with the latest lightweight construction material technology trends.  For you, this means an optimum implementation of your vehicle concepts, both technically and economically.  From the module to the complete vehicle, with EDAG your engineering challenge is in good hands.

Vehicle Package & concepts

The art of the package lies in arranging the components and modules in the vehicle in such a way as to ensure that geometrical and functional requirements are met. Today's cars have intelligent module structures that make it possible to provide the high number of vehicle variants demanded.

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This is one area in which you need the help of an engineering partner who, apart from making optimum use of the space available, will also look for the vehicle architecture that will provide the best possible ergonomic, assembly and maintenance properties. Besides this, we also carrying out complete vehicle benchmarking, to compare and assess concept-defining dimensions with competitors' vehicles for you.

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Body in white

New materials, including higher strength steels, and more stringent safety regulations – have had their effect on a vehicle's body in white.  The aim is always the same: optimum product performance at minimum cost and weight. 

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Our task is to ensure that no conflicting requirements arise between these new performance objectives and quality standards, while keeping in mind the rigors of series production.  We call this production-optimized development.

The first stage is usually virtual. We simulate the development concepts in order to optimize their stiffness, strength, safety, crash performance and of course feasibility. Following this, our test department carries out the validation process.

The development procedure is part of our tried and tested process landscape. From the approval procedure, parts list and the monitoring of deadlines, cost and weight, to change management, assembly support and supplier management – we accept responsibility for the development of complete bodies in white, and act as a system integrator at all relevant interfaces.

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Doors, lids, gates

Over the years, door, lid and gate systems have developed into highly complex modules. The aim is to meet not only the technical, but also the ergonomic and legal requirements, of the module. 

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To ensure that the design will not have to be altered at a later date, attention is paid to the joints and to assuring technical feasibility during the design validation phase.

Our development work focuses just as much on areas such as acoustics (e.g. wind noise) or ease of locking as it does, for instance, on side-impact protection protection: from the concept phase, design, simulation and validation, through to the finished series product.  

In addition, we also work on innovative material concepts for vehicle manufacturers and system suppliers, to meet product requirements that might not yet be important, but very soon will be.

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Interior

The customer's comfort plays a central role in the development of interior components. The car needs to feel right as soon as he gets into it for the first time.  It must be feeling that is typical for that particular brand of car and clearly distinguishes it from other brands. At EDAG, we know what to do to ensure that the first, decisive impression is positive.

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And, of course, we know that it is not simply a matter of the quality of the materials and how they are used.  We bring quality, functionality, ergonomics, manufacturability and stringent safety requirements into harmony with each other.  And, of course, we also keep an eye on costs, deadlines, product specifications and legal requirements.

From the earliest stages of a project, we apply ourselves to matters such as styling feasibility, spacial, and ergonomic evaluations, and the drawing up of technical specifications, to ensure that the interior will make this decisive impression.  At later stages, our experienced, interior engineers continue this process with the design layout of the components and modules, including, for instance, the instrument panel or door trims.

Depending on the agreed upon project responsibilities, we can take on the management of the system suppliers for you, and the responsibility for module development with the achievement of functional targets.

We offer the following solutions and services to meet your needs:

  • Project and interface management
  • Benchmark analysis
  • Class A Math Development – Studio Surfacing, Refinement, Solid Math
  • Design validation
  • Prototype and series design
  • Functional integration and validation
  • Creation of component specifications and guaranteeing adherence to these
  • Supplier and development management
  • Data management
  • Prototype and SOP build support
  • Continual quality surveillance and improvement (lessons learned, problem tracking)
  • Adherence to product targets
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Exterior

What applies for the interior applies equally for the exterior: the outward appearance presented by a car must conform with the values typical of the particular brand. The same also applies to the development of the add-on parts. For spoilers, panels, windows, glass roof systems or complete modules, e.g. bumper systems, we are the engineering specialists for add-on parts.

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In addition, working within a network of OEMs, suppliers and tool makers, we also guarantee active and passive safety requirements, for instance for passenger and pedestrian protection.

We offer the following solutions and services to meet your needs:

  • Project and interface management
  • Benchmark analysis
  • Package and concept development
  • Design validation
  • Prototype and series design
  • Functional integration and validation
  • Creation of component specifications and guaranteeing adherence to these
  • Supplier and development management (design, GD&T, deadlines, costs, weight, simulation, test & validation)
  • Guaranteeing legal and in-house requirements
  • Data management
  • Prototype assembly and SOP support
  • Continual quality surveillance and improvement (lessons learned, problem tracking)
  • Guaranteeing and adherence to product targets
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Light & Sight

There is probably no component that makes a more marked contribution to the appearance of a car than its lights. They give a vehicle character and its own unique expression. Whether they are refined, grand, friendly or even aggressive - the lights are the "eyes" of a car, and are today optimised to give the desired effect.

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For us, light development begins with the first design studies, followed by extensive simulation methods. Using specially designed software tools, we analyse and optimise the target light design so that it is physically correct. The advantage of this virtual simulation is that the impression the lights will later make can be examined well before the first prototype is made. Apart from dealing with the layout of optical components, the virtual validation of legal requirements is also carried out here. After prototype or series design, control units and the appropriate software are developed in the Electronics department. To guarantee the operational reliability of the components while they are being operated, we then carry out a complete thermal design with the most suitable cooling processes and material tests. Both for complete systems and for components.

We offer the following solutions and services to meet your needs:

  • Design studies
  • Light visualisation and simulation for prototype and series production
  • Functional, ambient and accent lighting
  • Design validation
  • Design prototyping and show car lights
  • Prototype and series design
  • Physical layout
  • Hardware and software development
  • E/E for concept and show cars
  • Headlight conversions
  • Thermal systems, engineering and simulation
  • Material testing
  • Certification ability
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Dimensional Management/GD&T

The vehicle’s product design, manufacturing processes, and quality control systems must all be defined so as to minimize and account for the dimensional variations that can be expected to occur in production.  

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Mathematic simulations can be performed as the design is matured to predict the compliance of the produced vehicle to dimensional specifications, with recommended changes to the design where warranted.  

Adding the supporting GD&T to the 2D component and assembly drawings is necessary to guide the construction of dimensional checking fixtures and to further define the quality control routines required.

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Digital Mock-Up (DMU)

It goes without saying that two components cannot occupy the same space at the same time. The Digital Mock-up process is used at predetermined points in the product development process to prevent this from occurring once the parts are manufactured and assembled. 

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As the DMU check approaches, the 3D digital math must be synched to revision level and digitally frozen. An individual is assigned to create a math assemblage of all mating and surrounding components at a compartment (specific area of the vehicle) or total vehicle level. All instances of less than required clearances or interferences are noted, documented, and assigned to owners of the component math for resolution.

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