As part of an innovative new project to demonstrate the capability of components built using state-of-the-art Rapid Prototyping technologies, Crucible Ltd have redesigned the font end of the SMART car using the latest product design tools and processes. Components for the updated design of the car were built using Selective Laser Sintering (SLS), fitted to an original SMART car and then driven across the breadth of the UK to prove their practicality. The success of the project has not only actively demonstrated the capabilities of Crucible’s product design processes and technology, but has revealed tremendous opportunities for the future design development and customisation of cars.
Crucible have a substantial track record of delivering exciting commercially competitive products within the consumer, scientific and medical markets. They approached the redesign of the SMART car from a product design perspective that includes considering the SMART brand, market and car design, as well as the car’s existing critical points and the functionality of the finished components.
All the detailed design development was carried out with 3D computer modelling, using Solid Works. Mike Ayre, Managing Director of Crucible comments, “With this project we have really stretched the abilities of Solid Works and Photo Works. A tremendous amount of complex surface modelling work went into creating forms, which would then fit over the basic chassis, particularly around the windscreen pillars and the headlights. It was also important that the flow of the lines of the car was maintained and this really involved pushing the abilities of the software to its full extent. We completed the project, from briefing, feasibility studies, initial sketches and concepts, through to design development in less than 20 days.”
The SMART ethos encompasses the customisation of SMART cars by replacing body panels with new colours. This project has extended the concept further and shows the future potential for customised body components. Crucible’s updated design has preserved the integrity of the SMART’s original design, whilst providing it with a fresh contemporary, more aggressive appearance. The success of the project has not only proven the durability of the SLS components in a true working environment, but also the technical viability of Crucible’s design. |
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