�Automotive Exteriors

An example of one product I designed was the liftgate for the 2000 Ford Windstar.

Beginning with the full size clay scan of the vehicle in the design studio, I created the Class-A surfaces for the 1st surface from cross sectional curves. These surfaces were milled into a neighboring verification clay model to determine that manufacturing meets design intent. It required that the roof sheet metal and side glass surfaces from the carry-over parts of the existing production models align with the new design theme. New rear windows, airfoil, and tailights were fit with exact cut line gaps. A new licesne plate assembly made of ABS was designed in the computer from scratch, then milled into clay. Design changes were done on the "tube" and verified in succesive clay mills. The SMC (sheet molded compound) liftgate needed to clear the rear fascia (bumper) during opening and closing and allow for a larger gap for "overslam" and NVH (noise, vibration, and harshness) during driving conditions, so studies were done to verify these requirements. Vision studies were done to determine that the CHMSL (Center Hi-Mount Stop Lamp) meet federal FMVSS regulations.

Design changes were done in the day, milled at night, and then inspected by the Studio Design Directors, Executive V.P.'s, and CEO on the following morning.

All in a days work.