Brief
We were tasked with creating a stylish, economical, entrance and drivers environment, with excellent ergonomics. The concept should be efficient to manufacture, install and maintain, it should be lightweight and transfer readily to production status.

Discussion Stage
A series of round-table discussions established the parameters around which the project would develop. The result was a series of initial schematics identifying the main design criteria and probable tooling requirements. At this stage too, materials were discussed including colours, textures and technical specifications.

CAD Modelling Stage
Using the schematics as a base line, we created CAD models around the structural models of the vehicle manufacturer. At this point, careful consideration was given to crucial aspects of the designs, ergonomics, legal requirements, and to the ultimate assembly of parts.

Prototype (or soft) Tooling
With the CAD models signed off, over fifty tools were manufactured within a matter of weeks. Due to time constraints the tooling work was shared, some made in-house using our 5-axis machining centres and some sub-contracted. Effectively demonstrating the close co-operation and seamless integration of customer/supplier systems.

Prototype Manufacture
This stage required a wide range of disciplines; vacuum forming, silk screen printing, routing, line and drape forming, hand and CNC trimming plus assembly. All the items were produced to an extremely tight schedule, and were a testimony to skill and dedication of all involved, including first line sub-contractors. The careful execution of the CAD work meant that components were reassuringly right first time.

Additional Items
As with any large project, items beyond those originally envisaged were required. Because the customer shared engineering models with us, we were well placed to rapidly create additional parts as they arose; wheelarch trims, skirts and light clusters are amongst examples of such items.

And so into production . . .
With the concept proven and the prototypes well received all that remained was to manufacture production tooling for the Esteem; aluminium forming tools, CNC trim and assembly jigs. Working closely with the customer and converting tools only as required, disruption and costs will be kept to a minimum. Delivering a cost efficeint stylish environment for passengers and staff, that is easy to install and maintain.