Objective
- Engineer a next-generation USPS delivery vehicle using advanced materials and manufacturing techniques.
- Apply DFA/DFM principles to streamline design and enhance manufacturability.
- Enable styling flexibility within robust structural constraints.
- Support modular assembly for scalable production and serviceability.
Conceptural Ideation
3D CAD Model
Solutions
- Compression Molding: Metton®, FRP
- SMC (Sheet Molding Compound) & RIM (Reaction Injection Molding) applications
- Low-Volume Manufacturing Strategies: Tailored for pilot builds, specialty fleets, and regional deployment
- Modular Design Integration: Facilitates part interchangeability and future upgrades
CAE Model
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3D Rendering
Results
- Engineered a Hybrid Aluminum/Composite Vehicle Structure for optimal strength-to-weight ratio.
- Achieved 40% reduction in part count and assembly complexity.
- Developed Class “A” co-injection thermoplastic body panels with high surface quality and durability.
- Introduced a modular fastening strategy enabling scalable, service-friendly assembly.
Ergonomic Buck
