An Introduction to

CAR TERMINOLOGY AND

FEATURES

PILE UP BY

SENTHUR & RAM

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 CONTENTS

• CAR BASIC TERMINOLOGY

• STAGES OF PRODUCT DEVELOPMENT
• INTERIORS AND CONSOLES
• DISCUSSIONS

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CONSTRUCTION TYPES

CONVENTIONAL BODY –OVER –FRAME

UNIBODY/SINGLE BODY

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UNIBODY TYPE

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 CAR FRONT BODY
• ENGINE HOOD
• COWL ASSY/HOOD HINGES
• FRONT FENDER
• RADIATOR UPPER SUPPORT
• RADIATOR SIDE SUPPORT
• FRONT CROSS MEMBER
• FRONT SIDE MEMBERS
• DASH PANEL
• FRONT FLOOR PANEL

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 CAR REAR BODY
• BACK DOOR PANEL
• LOWER BACK PANEL
• REAR FENDER
• REAR FLOOR PANEL
• TRUNK OR BOOT
• REAR BUMPER

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 BASIC CAR TERMINOLOGIES
D pillar

A pillar : the front pillar on a car's "greenhouse

B pillar : the second pillar of a car's greenhouse, usually separating the front and
rear door on a standard 4 door style sedan.
C pillar : the third pillar of a car's greenhouse, usually joining the rear door of a
standard 4 door sedan to the backlight. 7
BASIC CAR FEATURES

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CAR FEATURES

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CAR HEADERS

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CAR ROOF PANELS

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 WIND SHIELD

WINDSHIELDS ARE PARTS MADE OF TEMPERED GLASS OF THICHNESS

VARYING FROM 1.8-2.8MM.
THE PRIMARY DUTY OF THE WIND SHIELD IS TO SAFEGUARD THE
OCCUPANTS OF THE CAR AGAINST WIND AND RAIN.
ITS IS PLACED IN THE PLASTICS WEB IN FRONT HEADER PART,AND IN
THE ‘A’ PILLAR AT THE SIDES.
PROVISIONS ARE MADE IN THE ‘A’ PILLAR TO ACCOMADATE THE
WINDSHIELD AT THE SIDES.
ALL THE CORNER OF THE WINDSHIELD ARE COVERED WITH
WEATHER STRIPS IN ORDER TO CONTROL RAINWATER CREEPAGE

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 CAR HOOD/BONNET

Bonnet or hood is a covering part of engine ,chassis,and other

internal parts.normally it is hinged to the cowl part.It is surrounded
with weather strips along its periphery with two sides resting on 13
fender .
 COWL ASSY

HOOD IS HINGED TO CAR COWL HOLDING

COWL ASSY FOR THE BONNET/HOOD
MOVEMENTS 14
 BUMPERS

• Bumpers are formed to specific shapes in order to

absorb and deliver (Energy) momentum during a
collision.
• Bumpers absorbs some of the impact, which
decreases damage to the car and its occupants.
• Bumpers are provided with shock absorber ,In slow
speed collisions, this allows the bumper to compress,
and then extend back to its original position.
• Bumpers are provided on Front & Rear Sides.
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 FRONT BUMPERS

MATERIALS : ABS PLASTICS /POLYURETHANE/

FIBRE REINFORCED PLASTICS(FRP’S).
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 REAR BUMPERS

MATERIALS : ABS PLASTICS /POLYURETHANE/

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FIBRE REINFORCED PLASTICS(FRP’S).
 FENDER

FENDER IS A PART USUALLY MADE UP OF THIN ALUMINIUM SHEET WITH

CHROMEPLATED ABS ON SURFACE.ITS SHAPE IS DERIVED FROM BONNET
OR HOOD ON ONE SIDE AND WHEEL CURVATURE ON THE OTHER SIDE.IT
IS NORMALLY WELDED TO APRON OF THE CAR FRONT BODY.

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 HEAD LAMPS
BEZEL

REFLECTOR

PC LENS

5TH GENERATION DE MODULE (AFS)

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 LIGHTING DEVICES

TYPES OF LIGTING DEVICES IN MARKET

1. HALOGEN BULB.
2. XENON VERSION.
3. VARIOX XENON.
4. PRE AFS MODULE.

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 HEADLAMPS PARTS

TYPICAL HEADLAMP CONSISTS OF

HOUSING
HOUSING IS A PART WHICH HOLDS ENTIRE LIGHTING SYSTEMS.IT IS
FIXED WITH 4 MOUNTING DEVICES TO FENDER APRON.AND IT HAS 2
CIRCULAR OPENINGS FOR HIGH BEAM AND LOW BEAM MODULES.IT
IS MADE UP OF PP COPOLYMER
REFLECTOR
REFLECTOR IS THE MAIN PART OF A HEADLAMP UNIT WHICH IS
SECURED IN THE HOUSING.IT HAS A PARABOLIC LIGTING SURFACES
HAVING RECTANGULAR SERATION ALONG ITS PERIPHERY.THESE
SURFACES ARE ‘A’ CLASS SURFACES CONSTRUCTED IN ALIYAS.THIS
IS THE SURFACE WHICH REFLECTS THE LIGHT IN BEAM.THE
MATERIAL USED FOR THIS CHROMATED PP. 21
 HEAD LAMPS PARTS
LENS
ITS MADE UP OF POLYCARBONATE,A EXCELLENT TRANSPARENT PLASTICS.IT
CAN BE OF GLASS ALSO.NOW A DAYS CLEAR LENS ARE USED IN SUV CARS WITH
THE LIGHTING SERATION IN THE REFLECTOR.
THE LENS COVERS THE ENTIRE LIGHTING SYSTEMS,DUE TO ITS TRANSPARENCY ITS
REFRACTS THE LIGHT OUTPUT IN A SYNCHRONIZED MANNER.THE FRONT
PROJECTED AREA OF THE LENS IS ‘A ‘ CLASS SURFACE.
THE LENS IS GLUED TO THE HOUSING BY SPECIAL ADHESIVES.
BEZEL
IT IS MADE OF HIGH CLASS EPDM/ABS COMPOSITE PLASTICS.THE
PRIMARY FUNCTION OF A BEZEL IS TO COVER NON-LIGHTING AREA.ITA AN ENTIRE
STYLING PART OF A HEADLAMP.THE ENTIRE AESTHETIC LOOK OF HEADLAMP RELY
ON THIS PART.
MORE IMPORTANCE IS GIVEN FOR ITS STYLING.

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 FLOOR SILL

THE SILL IS THE BOTTOM EDGE OF A CAR

IT IS WELDED ON TO THE FLOOR PANELS
IT IS MADE UP OF ALUMINIUM DIPPED HIGH DENSITY ALLOY STEEL IN
ORDER TO WITHSTAND CORROSIVENESS
SILL SEAM IS THE LINE FORMED BETWEEN THE DOOR PANELS AND SILL
PART .IT IS NORMALLY EMBEDDED WITH WEATHER STRIPS MADE UP
OF RUBBER.
THE LENGTH OF THE FLOOR SILL IS UPTO THE WHEEL WING APRON
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SIDE PANEL

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Door panel

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 AUTOMOTIVE FUEL TANK

THIS IS A TYPICAL PLASTICS FUEL TANK.

NORMALLY NOW-A-DAYS FUEL TANK S ARE ALL MADE UP OF PLASTICS
THE MATERIAL FOR THAT IS HDPE COPOLYMER
THE ADVANTAGE OF PLASTICS HERE IS DUE TO ITS HIGH CORROSIVE
PROPETIES AND MANUFACTUREING FEASIBLITY INTO INTRICATE SHAPES
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 DIFFERENT FEATURES AND
MATERIAL
CAR TRUNK
CAR ROOF REAR END
BIW PANEL

HOOD

FRONT
BUMPER
BRACKET

REAR FENDER

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FRONT FENDER DOOR PANELS
CAR FEATURES AND MATL.DISTRIBUTION

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FEATURES CHART

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 BODY IN WHITE CONCEPT

THE BODY IN WHITE IS THE CORE SHELL OF THE CAR

NORMALLY MADE OF ALUMINIUM SPECIAL ALLOY STEEL
THESE ARE PATTENDED MODELS
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FROM THESE BODY EXTERIOR AND INTERIOR PARTS ARE DEVELOPED
FRONT BIW

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REAR BIW

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SIDE BIW

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TYPICAL BIW WITH PILLARS

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CAR BODY FRONT BIW FLOOR
PANEL

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 BUILDING CONCEPTS

• Normally BIW’s are made of aluminium alloy

or special molybdenum steels.
• Due to lighter weights and non-corrosive
properties aluminium is considered.

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SKETCHING

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CLAY AND PORCELAIN
MODELLING

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 INITIAL DEVELOPMENT
• AS THE STYLING SHAPE OF THE CAR IS
FINALISED ,THEN THE SCANNED TIFF DATA IS
SENT TO 3D -STUDIO MAX, HYPERMESH.
• THERE WITH THE HELP OF THE SCANNED
POINTS,STYLING IS OPTIMISED AND ENRICHED.
• THEN EACH AND EVERY VIEW OF CAR IS STYLED
THERE AS AN IMAGED VIEW.
• HYPERMESH IS USED TO MAKE PRE ANALYSIS OF
PERFORMANCE AND FUNCTIONALITY TO AVOID COST IN
CONCEPT DEVELOPING AND IN TROUBLESHOOTING

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 THE REALITY

• THEN COMES THE IMAGINATIONS INTO REALITY.THE

SCANNED DATA FROM THE MESH ARE TAKEN TO THE
HIGH END SOFT TOOL LIKE ICEMSURF, ENOVIA.
• FROM THE DATA CLOUDS OF POINTS ARE CREATED,AND
THE POINTS ARE TAKEN TO CREATE INITIAL SURFACES
• FROM THE STYLING CONCEPT,BIW IS DEVELOPED FIRST
(THE CORE SHELL OF THE BODY)AND ITS EMBEDDED WITH
EXTERIORS AND INTERIORS

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INTERIOR PANEL AND CONSOLES

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 INTERIOR PANEL

All the upholstery and molding which is

embedded over the body shell to give
aesthetic appearance are called interior
panel.

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 INTERIOR PANEL TYPES

INSTRUMENT PANEL
AC PANEL
DOOR PANEL
DASHBOARD PANEL

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 INSTRUMENT PANEL

A TYPICAL INSTRUMENT PANEL MADE OF ABS PLASTICS.ITS AN

ADDED PART OF A DASHBOARD PANEL

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 AC PANEL

A TYPICAL AC PANEL MADE OF ABS RESIN.

TESE INCLUDES AIR VENT, TRAY .ETC
ITS AN HYBRID PART OF DASHPOD PANEL

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 DOOR PANEL
EXTERIOR
PANEL

ARM REST
INNER ASSY.
TRIM
SLOTS

PLASTICS IP
TRIM 46
 DOOR TRIMS

OVAL TRIM
FOR ARMREST

TRIMS DONE
ON FOR
HANDLES

DOOR TRIMS ARE MADE UP OF PVC SHEETS, PP, POLYURETHANE,WHICH ARE

TRIMMED TO REQUIRED SHAPES FOR FEASIBLITY.THESE ARE THEN
ATTACHED TO PLASTICS OR SHEETMETAL HYBRID.PROVISIONS AND
OPENINGS ARE MADE FOR HANDLES AND ACCESSORIES 47
INNER DOOR TRIMS

DOOR IP TRIM

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TYPICAL DOOR TRIM

POLYURETHANE
UPHOLSTERY

PADDER OR ARM REST

HYBRID
TRIM
MADE OF
PP

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 WHAT ARE CONSOLES?

CONSOLES ARE THE PARTS WHICH

ADDS AESTHETIC LOOK AND
COMFORT FOR THE OCCUPANTS.IT IS
EMBEDDED OVER PLASTIC OR
METAL PANEL.

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 CONSOLES TYPES

-floor consoles
- overhead roof consoles
- seat consoles and desks
- dashboard consoles
- door pockets
- cargo storage drawers

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 DASHBOARD CONSOLE

The dashboard pod is a binnacle that sits on top of the dashboard and is ideal
for mounting a radio, CB extension speaker etc. It is a small version of the
instrument pod that houses the speedometer which comes standard in all
vehicles. Dash pods are finished in a vinyl that matches the dashboard52crash
pad. Most crash pads have a vacuum formed finish.
DOOR TRIMS WITH CONSOLE

DOOR CONSOLE
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 INTERIOR CONSOLES

CENTER
CONSOLE

STORAGE
BIN

CONSOLES
FLOOR
CONSOLES

It comes complete with a storage bin and a hinged lid that forms a padded armrest.
The storage bin is upholstered on the inside and includes a removable lining that is
held in place by Velcro tape.
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 CENTER FLOOR CONSOLE

Half Length Center Floor Console

Available for all transmission types, column shift, manual floor shift, and automatic
floor shift. Suitable for bench or bucket seats. This design sits neatly under the
dashboard and supplies as much flat facia as possible 55
 AESTHETIC CONSOLES

INST.PANEL

POLYURETHANE 56
FOAM CONSOLES
ANY SUGESSTIONS PLEASE

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THANK YOU !

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