Projects Details
This project addressed a common automotive OEM challenge: integrating multiple electrical features into a large headliner component that is difficult to handle in manufacturing and assembly.
The headliner is the soft lining above the passenger area. It is a large, prominent part that conceals electrical features and safety devices, while also needing to meet demanding quality requirements.
Q5D developed a wire arrangement in ribbon-like patterns that reduced the overall height of the assembly and improved integration into the part.
The approach increased passenger space by saving 8 to 12 mm in height. It also reduced weight at the highest point in the vehicle, removed the requirement for noise, vibration and harshness (NVH) tape and resulted in reduced wire consumption.
The resulting assembly was made more resilient to high vibration and large temperature swings. Passenger comfort was improved by removing rattles, smells and visual flaws while increasing the space available for functional and aesthetic features.
Assembly quality was also improved on a part that is often non-serviceable once installed, making manufacturing errors costly.
Benefits
- Saved 8 to 12 mm in height
- Reduced weight at the highest point in the vehicle
- Removed NVH tape requirement
- Reduced wire consumption
- Improved resilience to vibration and temperature swings
- Improved passenger comfort
- Improved assembly quality
- Reduced labour cost and supply-chain complexity
