We stand as your trusted partner in automotive design services, committed to delivering advanced automotive component design and simulation solutions. Our expertise lies in the development of tooling for body-in-white (BIW) component assembly, including fixtures, grippers, and various equipment. By focusing on precision and reliability, our tools enable manufacturers to optimize operations, boost productivity, and uphold the highest standards in automotive product design and assembly.
We proactively address common industry challenges to ensure seamless production and efficient outcomes. Our solutions specifically tackle:
Complex tooling designs.
Lengthy process validation and finalization stages.
High costs associated with manufacturing.
Tedious trial and testing phases.
Maintenance difficulties and limited accessibility.
Variations in product quality.
Unstable structures that cause occasional inconsistencies.
Certification ensures that we comply with the severe security demands generated by the automobile industry.
ISO 27001:2022: Ensuring robust information security management systems and compliance.
Customization for automotive service designing so that various client needs can be addressed.
Technology integration in creating proprietary in-house APIs for faster and more accurate outputs.
Ergonomic Designs: Keeping the ultimate comfort and safety of the user in mind so that the output meets all requirements.
ISO 27001:2022 certified: Ensuring highest detailing standards with stringent QC/QA checks at every stage.
Customization for automotive service designing so that various client needs can be addressed.
Stringent QC/QA checks at every stage to ensure accuracy and reliability.
Customization for automotive service designing so that various client needs can be addressed.
Technology integration in creating proprietary in-house APIs for faster and more accurate outputs.
Dedicated teams for Designing, QC/QA, Documentation, and more.
Managing all RFIs and effectively managing design revisions.
Our expertise lies in consistently identifying and addressing tooling requirements through innovative conceptual designs and robust validation processes. We offer:
Identification of new tooling requirements and creation of cutting-edge conceptual designs.
Validation of designs through CAE, ergonomic studies, and weld spot distribution analysis.
Preparation of detailed layouts with control charts and pneumatic circuits.
Flexible adaptation to various product variants.
Comprehensive solutions for manual and robotic workflows suitable for different production scales.
Simplification of processes to minimize complexity.
We possess vast experience dealing with a variety of challenges in the automotive industry particularly focused on tooling for the body-in-white assembly process. We have developed solutions that accommodate various joining processes, including:
Precision Positioning Fixture: Ensures that components are placed and aligned accurately for welding, gluing, and screwing.
Modular Fixtures: Flexible and reconfigurable designs can accommodate multiple part variations.
Ergonomic Fixtures: The ergonomic considerations are aimed at increasing the user-friendliness of the fixture while lowering operator fatigue.
Robotic Grippers: Custom grippers that can handle parts for high-speed production lines.
Adaptive Grippers: A solution designed for handling components that assume variable shapes and sizes.
Lightweight Grippers: Using advanced materials such as carbon fiber to minimize load on the load carriers while maximizing durability.
Spot Welding: Tools for precision and consistency in the design of automotive components.
Adhesive Bonding: Devices optimized for a consistently even adhesive application, preventing potential leaks or undesired action.
Riveting and Screwing: Accurately align and securely fasten the mechanical joining method.
Laser Welding: Specialized apparatuses designed to uphold highly precise laser welding applications.
Conveyor Systems: Designing tooling compatible with conveyor-style material handling systems.
Part Transfer Systems: Tools ensuring component smooth and accurate transfer between workstations.
Lift and Rotate Mechanisms: Designing mechanisms that accommodate the complex movements of assembling.
Flexibility: Tools that can be adapted for different vehicle models or configurations.
Scalability: Solutions capable of providing production with the capacity to run in small batches or volume.
Validation of Virtual Tools: Digital twin technology is applied for simulating tooling performance and validating its potency before actual manufacture.
Kinematics Analysis: Allows for the dynamic operation of tools without interference or misalignment.
Cycle Time Optimization: Simulating downtime during production cycles to improve productivity.
Stress and Load Testing: Simulations seek to put tools under the load of practical conditions to ensure the tools’ viability under adverse situations.
We employ the best available programs for the design, analysis, and simulation of tool systems. These sophisticated tools enable visualization of complex designs, feasibility evaluation, and simulation of real-life conditions to ensure optimal performance. Commonly used software includes:
Tools like CATIA, NX, FIDES, SOLIDWORKS, and AutoCAD for detailed automotive parts design and modeling.
ROBCAD, PROCESS SIMULATE, DELMIA, 3D Experience, ROBOGUIDE.
FEA analysis with ANSYS and HYPERMESH.
Using these advanced tools helps us create precise, functional machines. These machines effectively solve challenges
in chassis structure design and more.
The emphasis in a technical sense is on the provision of robust and accurate tools. The primary components include:
Our area of expertise is in designing and simulating tooling solutions for use in body-in-white assembly. Our prime area of focus is:
To ensure the highest levels of quality and performance, we strictly adhere to:
Ergonomic Safety Standards: Tools shall be designed to ensure operator safety and ease of maintenance.
Best Industry Practices: Following tried and tested methodologies in tooling design, automobile manufacturing, and deployment.
Compliance: Designs and processes are in full compliance with the applicable regulations and safety standards of the automotive industry.
Global Standards Expertise:
Designing tools that comply with international and OEM/tire suppliers-specific standards (e.g., ISO, ASTM, DIN, NAAMS, BMW, DAIMLER, VW, JLR, GM, FORD, AUDI, PORSCHE, FERRARI, ROLLS-ROYCE, TESLA, STELLANTIS, VALMET, GESTAMP, MAGNA, EBZ, VDL, FFT).
Safety and Ergonomics:
Ensuring all designs meet strict safety and ergonomic guidelines for operators.
Lean Design Principles:
Specializing in reducing material wastage and optimizing manufacturing processes.
Rapid Prototyping:
Using advanced techniques for quick development of prototypes and pilot tools.
On-Site Support:
Providing technical assistance during the setup and operation of tools.
Upgrades and Retrofitting:
Offering solutions for enhancing or modernizing existing tooling systems.
Jaguar Land Rover (JLR) was looking to cue the assembly process for the Range Rover Velar GT EMA L481 model, concentrating on the production of critical body panels—wheelhouse rear quarter, Body Sides Inner (BSI), Body Sides Inner Reinforcement (BSIR), and Body Sides Outer (BSO). Ultimately, the prime goal was to optimize design and manufacturing processes in terms of efficiency, accuracy, and cycle time reduction.
In this project, the three main zones were classified as Z09, Z11, and Z12, each treating different parts of the body. BSI was produced in Z09, BSIR in Z11, and BSO in Z12. The major challenge was to maximize precision in the processes changed for different variant parts and to ensure an efficient assembly process that included adhesive application, spot welding, Arplas welding, and stud welding.
The team encountered many challenges, particularly with Arplas welding and the loading process, which was still being done manually. Z12 really needed a smooth production flow that could accommodate component variants; for instance, the RH BSO had two component variants (with and without a charge port), while the LH BSO had one variant (with a charge port).
Process optimization: In Z09, the manual feeding of parts took place via LCAs (turntables), whereas the rest of the parts manipulation was performed by the robots kept within the defined area. The GEO area for a specific model was aligned to position the parts for continuous flow through a common area toward the EMS.
In Z11, the layout constraints of RH and LH assemblies were cleared by optimizing weld stations and combining multiple stations into one, thus significantly reducing cycle time.
In Z12, the operational task managed to cross variant complexities through the unbroken flow of production. The panels were de-racked from containers and handled through LCAs, where robots made the assembly work in defined zones.
The replacement of the tool changer with a new robot increased efficiency and decreased the cycle time for welding at Arplas.
Despite the complexities, the Range Rover Velar GT EMA L481 project was commissioned smoothly without any assembly issues. Through process optimizations and innovative solutions, the team managed to reduce cycle time and improve efficiency and production flow. This finally resulted in a highly efficient assembly system with considerable customer appreciation for its seamless execution.
Valmet Automotive, one of the leading players in automotive manufacturing, started the S194 project with the aim of improving mechanical design and simulations of car panels. The areas of focus were Framing, C-D Pillar, Body Sides, and Body Side Subs, which made use of high-end welding technologies and very detailed engineering. The main objectives of the project were structural integrity, weight optimization, and durability, with the compliance of all applicable standards. Major hurdles were aligning properly during framing for maximum safety and aerodynamics, balancing welding techniques to ensure strength and reduction of weight, and integration of conflicting levels of panels for high production volume.
Framing car panel spot welding and CMT welding offered structural strength with little distortion. High-efficiency simulation tools have been used for optimizing the panel before production. C-D Pillar Car Panels needed CMT welding and riveting, providing extra strength and durability. The simulation models predicted stress distribution and optimized for joining concerning safety and manufacturability. On the Body Side Car Panel, CMT welding and riveting provided strength and flexibility. Precise robotic welding systems reduced defects and improved efficiency. The body side subs car panel was key in supporting the vehicle structure. It was decided to use MIG welding for its deep penetration and high-strength joints for crashworthiness and durability.
S194 accomplished the objective of improving durability through welding process optimization, enhancing production efficiency through material wastage reduction, and enabling high-precision assembly for superior vehicle functioning; yet this was accomplished with cost-effective production methods that do not compromise on quality. Using advanced mechanical design and simulation with Valmet Automotive now stands as the benchmark in the industry with the demonstration of precision engineering power.
This project displays how advancements in design, simulation, and welding techniques transform vehicle manufacturing. As technology moves forward, Valmet Automotive stays committed to engineering excellence in which each vehicle is built to a top standard of strength, safety, and performance.
Copyrights 2025 Moldtek Technologies.
Copyrights 2025 Moldtek Technologies.