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DESIGN
COMPUTER AIDED DESIGN (CAD)
CAD is the term used to describe the method by which objects are designed using machines or equipment controlled by computer-based software. The advantages of CAD include:
- The ability to producing very accurate designs
- Drawings can be created in 2D or 3D and rotated
- Other computer programmes can be linked to the design software
Computer-based software can also be used to control machines or equipment during the manufacturing process. This is known as Computer Aided Manufacturing (CAM).
ERGONOMICS
Ergonomics is the science of designing objects and environments that are ideally suited to the needs of people. For example, the MINI is adapted to its driver, not the other way around. All operating and display elements, such as the speedometer and electric window switches, are positioned in a way that they can be seen or operated easily. Ergonomics ensures that a driver is comfortable and can improve safety as the driver's attention is not distracted by searching for a display or function.
PRODUCT DESIGN SPECIFICATION
The first step in the design process is typically to create a product design specification, which is a document giving details of what a product is supposed to do. This is then given to the design team, who will develop a design sketch.
MOCK-UP
A scale model constructed for the purpose of testing a design is known as a mock-up. A mock-up is used to test how a design looks, rather than how it works, and is often made from clay.
PROTOTYPE
The next step is the development of an actual-size, fully functional model of a product, known as a prototype. Prototypes can be costly to produce but are an essential part of the research and development process. By testing a prototype, engineers and designers will be able to find out if their design works. Not all prototypes make it through to production.
MATERIALS
BODYSHELL
Vehicles can be made from many types of materials, but all must be strong, light and easily formed into complex shapes. In a MINI, high strength steels and aluminium components in the door area are used to make it more able to withstand the impact of a crash.
CARBON FIBRE
Carbon fibre is a synthetic material made from fibres of carbon, which are about 0.005-0.010 mm in diameter – thinner than a human hair. The fibres are joined to form a mat-like fabric that is very strong and lightweight. This makes it ideally suited for reinforcing parts of the car, without increasing the weight. However, carbon fibre is expensive to produce.
ALLOY WHEELS
An alloy is a material containing a mixture of two or more metals. A lightweight alloy of steel and aluminium or magnesium is often used for car wheels to reduce weight and therefore, increase the speed or handling of a car.
DARKENED GLASS
Darkened glass can be used for the rear windscreen and rear side windows to provide protection against light and heat to keep the car cooler, without reducing visibility.
RUN-FLAT TYRES
Reinforced tyre walls and heat resistant rubber can be used to give tyres emergency running properties, which mean that in the event of a puncture, an immediate tyre change is not necessary. In a MINI, 'Run-flat tyres', as they are known, make it possible to drive for approximately 150 km at a speed of 80 km/h with flat tyres.
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MINI Story
