International Journal of Science, Engineering and TechnologyAuthors: R. Sridhar, S. Jacob, T. GopalaKrishnan, K. Karunakaran, G. Sathish Kumar, Aravind Y, Arun Vikram M P
Abstract: The growing emphasis on lightweighting, cost efficiency, and ergonomic refinement in modern vehicles has intensified the need for computer-aided product design methodologies in interior component development. This study presents the computer-aided design (CAD) and manufacturability analysis of an automotive door trim panel using CATIA V5. The research outlines a structured workflow beginning with the import of a Class-A aesthetic surface, followed by the generation of Class-B and Class-C surfaces, definition of tooling axes, and incorporation of essential engineering features such as doghouses, push pins, heat stakes, and gussets to ensure assembly integrity and durability. A bottom-up assembly approach was employed to integrate the armrest, lower substrate, and map pocket into a unified structure. The manufacturability of the resulting geometry was verified through draft analysis, confirming adequate ejection feasibility and surface continuity for injection moulding. The findings highlight that applying a parametric and feature-driven CAD approach significantly enhances precision and design efficiency, ensuring compliance with design-for-manufacturing (DFM) standards. Furthermore, the proposed workflow demonstrates potential for reducing tooling errors, optimizing material usage, and supporting sustainable production by minimizing rework iterations. This research provides a replicable framework for transitioning conceptual surface designs into manufacturable components, with broader implications for ergonomics, cost reduction, and eco-friendly automotive interior design.
