BIW Design Course

Lesson 1 • Key BIW Assemblies and Subassemblies

Identifies underbody, body side, roof, and closure assemblies and their interfaces. Builds part-level recognition essential for detailed design chapters.

Lesson 2 • Materials Used in BIW Structures

Surveys steel grades, aluminium alloys, and advanced high-strength materials common in BIW. Connects material selection to weight, cost, and performance trade-offs.

Lesson 3 • BIW Design Process Overview

Maps the end-to-end design process from concept through production release. Orients students to phase gates, deliverables, and cross-functional dependencies.

Lesson 4 • BIW Functional Requirements

Examines load-bearing, safety, and NVH requirements that govern BIW design decisions. Links functional targets to structural choices made throughout the course.

Lesson 1 • Assembly Modelling and Constraints

Assembles BIW subassemblies using mating constraints and reference geometry. Proper assembly structure enables clash detection and design change management.

Lesson 2 • Surface Modelling for Outer Panels

Applies Class-A and structural surface techniques to model exterior BIW panels. Accurate surfaces are the foundation for tooling and die design.

Lesson 3 • Solid Modelling of Structural Members

Creates solid geometry for rails, pillars, and reinforcements using feature-based modelling. Solid accuracy drives correct mass, section, and joint behaviour.

Lesson 4 • CAD Environment Setup for BIW

Configures workspace, coordinate systems, and templates specific to BIW projects. Correct setup prevents downstream errors in assembly and analysis.

Lesson 1 • Springback and Compensation Strategies

Analyses springback causes and applies overbend and die compensation methods. Managing springback is critical for achieving dimensional accuracy in BIW assemblies.

Lesson 2 • Flanges, Hems, and Seams

Designs flanges, hem folds, and seam joints that meet assembly and sealing requirements. These features appear on nearly every BIW closure and panel.

Lesson 3 • Design Rules for Stampings

Applies minimum bend radius, draft angle, and hole-to-edge rules to BIW parts. Rule compliance reduces tooling cost and improves part quality.

Lesson 4 • Sheet Metal Forming Fundamentals

Explains stamping, deep drawing, and roll-forming processes relevant to BIW panels. Process knowledge informs design decisions that prevent forming defects.

Lesson 1 • Joining Method Selection and Specification

Provides a decision framework for selecting and documenting joining methods on BIW drawings. Systematic specification prevents assembly errors and supports process validation.

Lesson 2 • MIG, MAG, and Laser Welding

Examines continuous weld processes used for structural joints and closures in BIW. Process selection affects distortion, cycle time, and joint strength.

Lesson 3 • Resistance Spot Welding Design

Covers spot weld nugget sizing, pitch, and flange width requirements for BIW joints. Correct spot weld design ensures structural integrity and weld gun access.

Lesson 4 • Mechanical Fastening Methods

Reviews self-piercing rivets, flow-drill screws, and clinching for BIW assembly. Mechanical fasteners are essential where welding is impractical or material-incompatible.

Lesson 1 • Section Property Optimisation

Calculates and optimises cross-section moment of inertia and section modulus for BIW members. Optimised sections achieve stiffness targets with minimum mass.

Lesson 2 • Crash and Impact Performance Design

Designs crush zones, trigger features, and reinforcements to meet crash energy targets. Crash performance is a primary driver of BIW structural architecture.

Lesson 3 • Finite Element Analysis Basics for BIW

Introduces FEA mesh types, boundary conditions, and load cases relevant to BIW structures. FEA results guide design decisions covered in subsequent sections.

Lesson 4 • NVH and Stiffness Optimisation

Applies modal analysis and stiffness targets to reduce noise, vibration, and harshness in BIW. NVH optimisation balances mass efficiency with acoustic performance.

Lesson 1 • Hinge and Latch System Design

Specifies hinge geometry, latch striker placement, and check-link integration for closures. Correct kinematics prevent interference and ensure reliable operation.

Lesson 2 • Sealing System Design

Designs primary and secondary seals, baffles, and drain paths for water and air management. Effective sealing prevents corrosion, noise ingress, and customer complaints.

Lesson 3 • Closure Panel Architecture

Defines inner, outer, and reinforcement panel configurations for doors, hoods, and decklids. Panel architecture determines stiffness, mass, and assembly sequence.

Lesson 4 • Closure Durability and Fatigue

Applies fatigue life requirements to hinge, latch, and panel designs for closure durability. Durability targets are validated through simulation and physical testing.

Lesson 1 • Variation Sources in BIW Assembly

Identifies part, tooling, and process variation sources that accumulate in BIW assemblies. Recognising variation sources is the first step in dimensional management.

Lesson 2 • Locating Strategies and Datum Systems

Applies 3-2-1 and RPS locating principles to BIW parts and assemblies. Consistent datum systems are essential for repeatable assembly and measurement.

Lesson 3 • Measurement and Dimensional Reporting

Applies CMM, optical scanning, and SPC methods to monitor BIW dimensional quality. Measurement data drives corrective action and continuous improvement.

Lesson 4 • Fixture and Tooling Design Principles

Designs welding fixtures and checking fixtures aligned with the BIW datum system. Fixture design directly controls assembly accuracy and repeatability.

Lesson 1 • Corrosion Protection Design

Designs drain holes, e-coat access, and cavity wax paths to ensure full corrosion protection. Corrosion design is validated through immersion and salt-spray testing.

Lesson 2 • Design for Assembly in BIW

Applies DFA principles to reduce part count, simplify assembly sequence, and improve access. DFA decisions made early prevent costly late-stage engineering changes.

Lesson 3 • Weight Reduction and Lightweighting

Applies topology optimisation, gauge reduction, and material substitution to reduce BIW mass. Lightweighting must be balanced against structural and cost constraints.

Lesson 4 • Design Review and DFMEA Process

Conducts structured design reviews and builds a Design Failure Mode and Effects Analysis for BIW. DFMEA identifies high-risk features before tooling commitment.