From Clay Model to Finished CFRP Fender: A Behind-the-Scenes Look at Vehicle Development

The development of modern vehicle bodies is a fascinating process that combines craftsmanship with cutting-edge technology. A particularly exciting part of this process is the journey from the initial model to the finished component – in our case, a painted CFRP fender produced in small series.

It often begins with a (painted) clay model. This physical model allows designers and engineers to experience and optimize the shape and proportions of a component tactilely. The paint on the clay model helps to realistically assess surface textures and reflections.

In the next step, the clay model is digitized using a 3D scan. This precise capture allows the physical form to be transferred into a digital model, which is then used for further processing steps in a CAD system.

Subsequently, refinement to a so-called Class-A surface takes place in CAD. Class-A surfaces are extremely high-quality surface models used for visible body parts that meet the highest demands for smoothness and aesthetics. This digital surface forms the basis for producing the component.

Finally, the fender is manufactured from CFRP and painted – specifically in a small series. CFRP not only offers impressive lightweight potential but also excellent stability and visual quality.

This thoughtful and precise development process shows how modern vehicle parts are created today: a combination of traditional modeling, digital technology, and innovative materials. This results in a high-quality, aesthetic, and functional component that meets the demands of modern vehicle development.