Automotive engineering and product development consulting

Automotive System Engineering and Development is the structured execution of mechanical engineering across complete vehicle systems, ensuring that function, performance, durability, and manufacturability are designed in from the start.
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In practice, it involves defining clear system architectures, interfaces, load paths, and requirements, then translating them into robust, production-ready designs using data-driven methods, thereby minimizing risk in production and use.

RD8 focuses on making automotive systems insensitive to manufacturing variation while meeting performance and durability targets at scale. This involves early tolerance allocation, clear kinematics, and structural assessment of interfaces and load paths, so critical functions remain stable across millions of units.

By embedding robustness into the design rather than relying on late fixes, engineering risk is reduced, production yield improves, and total cost is lowered without compromising vehicle performance.

Chassis and load-bearing systems define the vehicle’s structural backbone, carrying static and dynamic loads while ensuring stiffness, durability and crash performance. They are characterised by complex load paths, multi-axial stresses and tight interfaces between welded, bolted or cast components. A strong coupling exists between manufacturing processes and tolerances.

Development is challenged by competing targets for weight reduction, cost, structural integrity and manufacturability. Small deviations can lead to stress concentrations, misalignment or unpredictable system behaviour.

RD8 supports chassis and structural system development through Robust Design principles, focusing on kinematic architecture and interface definition, always maintaining tolerance optimization as a key ingredient of the product development.
This enables predictable load transfer, reduces overconstraints and creates designs that meet performance targets while remaining robust and production-ready at scale.

Mechatronic systems integrate precision mechanics with actuators and sensors, where interfaces, kinematics and tolerances directly impact car and passenger safety. They are characterised by tight coupling between mechanical architecture and control performance, minimal tolerance for variation, and strict lifetime requirements.

The development is challenging due to high sensitivity to geometric variation, reduced historical knowledge and very limited margin for late changes. Even small deviations can degrade system response or compromise function.

RD8 supports safety‑critical mechatronic systems by supplementing the SME knowledge with Robust Design principles, focusing on interfaces, kinematics and tolerance allocation. By eliminating overconstraints and reducing sensitivity early, RD8 enables predictable behaviour, fewer design iterations and robust, must‑not‑fail solutions suitable for autonomous driving at Level 3 or higher.

Propulsion and engine modules are dependent on complex load paths, rotating components, thermal effects and tight mechanical interfaces where efficiency, durability and NVH are critical. They combine high structural demands with sensitivity to assembly order and material behaviour under load and temperature.

Competing targets for performance, weight, cost and lifetime make development challenging, while small geometric deviations can lead to vibration, wear or reduced efficiency.

RD8 supports propulsion and engine modules through Robust Design principles, focusing on kinematic architecture, interface clarity and tolerance optimisation. This reduces sensitivity to variation, improves predictability and enables robust, production‑ready designs for high‑performance applications.