Product Design

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Concept to Production Engineering

Product Design

Melecs experts are widely involved in executing several turnkey projects for Automotive industry and Tier 1 suppliers all over the world. By providing complete range of product design, tool design and manufacturing end-to-end service to our customers.

Our strong experienced technical team has a decade of track record in the domain of concept styling, automotive interior, exterior trim, sheet metal, and engineered plastics.

We bridge the gap between initial industrial design and high-volume manufacturing feasibility, applying rigorous DFM/DFA analysis, GD&T tolerance stack-up, and prototyping to accelerate product delivery.

Our Commitment: We stick to quality, on time delivery and cost effective execution.
Automotive Product Design and Styling
INTERIOR SYSTEMS EXTERIOR TRIM DFM & DFA PLASTICS & SHEET METAL

Automotive Interior Systems

INTERIOR ENGINEERING

Full development of automotive interior systems from initial styling packaging to production-ready tooling data.

Concept Development & Packaging

01

Transforming interior styling surfaces into functional cabin assemblies while satisfying vehicle packaging boundaries, occupant safety standards, and ergonomic reach envelopes.

Core Capabilities & Scope
Concept Development Studies
Vehicle Cabin Packaging
Kinematics & Mechanism Studies
Cup Holders & Consoles
Door Trim & IP Subsystems
2D Release Drawing Creation

Tolerance Stack-Up & Quality

02

Comprehensive quality engineering to verify gap-and-flush conditions, clip retention, structural stiffness, and manufacturing process limits before cutting production tooling.

Engineering & Quality Scope
GD&T & Tolerance Stack-Up
DFM & DFA Studies
DFMEA & PFMEA Reviews
CAE Structural Analysis
Prototype Building & Fitment
Reverse Engineering & CAD Conv.

Class-A to Production Release

EXTERIOR ENGINEERING

Engineering exterior body trim, aerodynamic cladding, and structural bumper systems to withstand high environmental and impact stresses.

Bumpers, Fenders & Cladding

01

Complete design and engineering of automotive exterior systems from Class-A surface feasibility to production release. We engineer structural bumper assemblies, energy absorbers, pedestrian protection compliance, fascia split lines, and precision aerodynamic trim.

Core Capabilities & Scope
Design & Development of Bumpers
Design & Development of Fenders
Wheel Arch Liners & Rockers
Grilles & Air Intake Ducts
Spoilers & Aerodynamic Trim
Energy Absorber Integration

Tooling Validation & DFM

02

Rigorous tooling verification ensuring all exterior plastic and sheet metal parts meet stringent manufacturing feasibility standards. We optimize parting lines, draft angles, wall thickness variations, mold flow, and stamping drawability.

Manufacturing & Quality Scope
DFM & DFA Verification
DFMEA & PFMEA Risk Management
Injection Molding Feasibility
Sheet Metal Stamping Feasibility
GD&T & Tolerance Stack-Up
2D Production Release Drawings

Engineering Hierarchy

HOW WE DEVELOP PRODUCTS

A disciplined stage-gate process delivering seamless execution from early concept through manufacturing sign-off.

01

Concept & Study

Packaging boundaries, kinematic feasibility, benchmarking, and styling surface translation.

02

3D CAD Detailing

Solid and B-side surface modeling, ribbing structures, mounting bosses, and fastener layouts.

03

DFM & Tolerance

GD&T stack-up, draft analysis, DFMEA review, and mold tool interface verification.

04

Prototyping & Build

Rapid prototyping, physical fitment validation, production 2D drawing release, and tooling handoff.

Looking for Turnkey Product Design & Development?

Get in touch with our expert engineering team in Bangalore for complete product design, DFM analysis, and prototype execution.

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