Design a Unique Product Line for Your Brand in 60 Days
1.Project Background
Alex owns a renowned foreign company in the automotive industry, specializing in the R&D and manufacturing of high-performance automotive components. They sought cooperation with us to ODM a custom exhaust manifold for their new high-performance sports car. Positioned in the premium market, this sports car has extremely high requirements for power performance and driving experience. As a key component affecting engine exhaust efficiency and power output, the performance of the exhaust manifold is critical. The client required the entire process from design to sample delivery to be completed within 60 days to align with their new vehicle’s R&D schedule.
2.Project Target
Within the strict 60-day timeline, design and manufacture an exhaust manifold sample that meets the requirements of the client’s high-performance sports car. The exhaust manifold must exhibit efficient exhaust performance, excellent heat resistance and durability, while satisfying the client’s specific requirements for dimensions, weight, and installation interfaces.
3.Project Execution
Days 1–5: Requirement Research and Analysis
Form a project team comprising marketing, technical, and design personnel to conduct in-depth communication with the client to understand their specific requirements for the exhaust manifold’s performance, dimensions, materials, appearance, etc.
Collect technical data provided by the client, such as the sports car’s engine parameters and chassis layout, to provide a basis for subsequent design.
Research existing exhaust manifold technologies and products in the market, analyze competitors’ strengths and weaknesses, and provide references for innovative design of the project.
Days 6–10: Concept Design and Scheme Review
The design team uses advanced CAD software to carry out concept design of the exhaust manifold based on the research results, proposing multiple design schemes.
Organize internal experts to review the design schemes, evaluate and optimize them from multiple dimensions such as performance, manufacturing processes, and costs, and select the best scheme.
Submit the selected design scheme to the client for review, and make further modifications and improvements based on the client’s feedback.
Days 11–20: Detailed Design and Simulation Analysis
Complete the detailed design of the exhaust manifold, determine the specific dimensions, shapes, and connection methods of each component, and generate detailed engineering drawings.
Use CAE software to perform fluid dynamics analysis, thermal stress analysis, and structural strength analysis on the exhaust manifold to simulate its performance under different working conditions.
Optimize and adjust the design based on simulation results to ensure that the exhaust manifold meets performance requirements while having good reliability and durability.
Days 21–30: Mold Design and Manufacturing
Carry out mold design and manufacturing based on detailed design drawings. Select appropriate mold materials and processing techniques to ensure mold accuracy and quality.
Debug and optimize the mold multiple times to ensure it can accurately form each component of the exhaust manifold.
Meanwhile, sign raw material procurement contracts with suppliers to ensure timely supply and stable quality of raw materials.
Days 31–40: Sample Manufacturing and Inspection
Use the manufactured molds and purchased raw materials to begin manufacturing exhaust manifold samples. Produce strictly in accordance with process requirements to ensure quality control at each stage.
Conduct comprehensive inspections and tests on the manufactured samples, including dimensional measurement, appearance inspection, and performance testing.
Make necessary adjustments and repairs to the samples based on inspection and test results to ensure they fully meet design requirements.
Days 41–50: Performance Testing and Optimization
Install the samples on the engine test bench provided by the client for actual performance testing. Test items include key performance indicators such as exhaust backpressure, flow coefficient, and temperature distribution.
Further optimize and adjust the exhaust manifold based on test results, improving its exhaust performance by modifying the internal structure and adjusting pipe diameters and lengths.
Conduct performance tests again until the client’s specified performance standards are met.
Days 51–60: Final Delivery and Summary
Perform final cleaning, packaging, and labeling on the optimized and tested samples to ensure they are not damaged during transportation.
Deliver the samples to the client and provide detailed technical documents and test reports.
Organize the project team to summarize and review the project, analyze the experience and lessons learned during execution, and provide references for similar projects in the future.
4.What creates the success of this project?
Successfully designed and manufactured the required exhaust manifold sample within 60 days, meeting the client’s new vehicle R&D schedule.
Through actual testing, the performance indicators of the exhaust manifold met the client’s specified standards, effectively improving engine exhaust efficiency and power output.
Established a good cooperative relationship with the client through this project, gaining more business opportunities and reputation for the company in the international market.
