Design? Check!

The Audi e-tron GT design check – a new challenge for PSW?

TILO SCHIESTERL: It was at least a new task for us. Up until now, vehicles we develop undergo a design check carried out by Audi – in the case of the Audi e-tron GT, we did the design check ourselves for the first time. In basic terms, this is a physical vehicle structure, and is initially shown in prototype form. It is continuously updated with the corresponding versions from series vehicle development. This is done to test functionalities, check panel gaps, check installation sequences or customer service accessibility and a whole lot more. You have to do this live on the hardware. Moreover, our structure was electrified: in addition to the physical mock-up, we were also able to operate equipment and light the vehicle, for example, to depict ambient light and the night-time design. Electrification is also important to get a feel for the infotainment system.

MICHAEL WALKER: Right at the beginning, we had the so-called zero milled body shell, this is the entire vehicle body, including the interior, attachment points and many other components. In an ongoing process, we fitted many specific parts from suppliers, tried them out and removed them again. This adds up to hundreds of parts. And when it comes to the off-tool parts, this is where things get exciting: because tool production is cost-intensive, so everything really has to be just right – the look and feel, gap widths and so on. Of course you want everything to be perfect, and experience and gut feeling play a big role here.

EGID BEYER: Since not only the greenhouse was depicted in the design check, other items such as the cable loom, rear lights, boot lid, rear window and many other parts could also be included. It's all about usability, ergonomics and also about the strength of components. A lot of tinkering goes into the details, such as the parcel shelf, where the design of the ventilation grille enables the rear window to be optimally defrosted in a short time. The electrification, on the other hand, revealed other sticking points: despite the ambient lighting, no light reflections should appear in the driver's field of vision, this even concerns the colour of the seams in the leather upholstery.

MICHAEL WALKER: The design check is carried out in a product process phase where components are installed and specifically checked for the first time. Does everything work? We set up and carried out our design check in line with the tried and tested Audi processes. You can't do this without real hardware. But the design check – just like every process – will continue to develop, the digital part of the check will grow because it will reduce the amount of vehicle construction work.

TILO SCHIESTERL: Using VR tools we were able to view some updates virtually. This saves time and money and will definitely become more important. But real cubing will certainly continue in the premium segment. Look and feel, usability, experiencing the vehicle – all of this plays a major role.

EGID BEYER: Our colleagues from Audi were also involved in the process when it came to determining how the parts would be installed on the production line later on. We communicated with each other very well. Overall, it was a great collaboration with the colleagues from the Audi technical centre and planning department.

TILO SCHIESTERL: It was all very lean. We had one contact person at Audi for the entire interior. The coordination was pragmatic and uncomplicated, we went straight to the workshop and got to work together on the hardware. No showroom atmosphere, but with a strong garage feeling, everyone enjoyed it.

MICHAEL WALKER: We all got on really well, it's all about the functionality of the components. Egid set up the workshop for our design check from scratch, created a prototype-safe space with a security door system, and fitted and removed parts umpteen times. When it comes to the design check he really knows his stuff.

TILO SCHIESTERL: Absolutely. What Egid has done in terms of converting the workshop can only be done by a real mechanic and tinkerer, you have to be able to improvise and organize at the same time. Building a complete vehicle starting with a body shell so that it also works electrically – that really is a big deal!