Bumper System & Intelligent Perception Integration
Structural design and engineering delivery of front/rear bumpers for an EV model
We were responsible for the front/rear bumper assembly structural design and development for an EV model. The project coordinated multiple requirements — exterior styling, low-speed crash, pedestrian protection and ADAS sensor layout — and delivered directly mass-producible high-quality data through refined cross-section design and multiple rounds of tooling rectification.
--- Project Highlights ---
1. Styling fidelity & section refinement: Based on styling CAS data, through multiple clay and A-surface refinement rounds we accurately restored design intent and optimized bumper surface sections to balance aesthetic appearance with demolding process.
2. Low-speed crash & pedestrian protection: We designed front bumper energy-absorbing blocks and rear bumper anti-collision structures to meet zero-repair low-speed crash requirements and the latest pedestrian leg/head protection regulations, reducing accident repair cost and injury risk.
3. ADAS sensor fusion: Integrating mmWave radar and ultrasonic radar mounting structures in the front bumper area, we optimized the wave-transparent window and bracket stiffness to ensure L2+ ADAS sensing signal stability.
4. Tooling support & issue resolution: Throughout tooling development, we performed CAE analysis and structural optimization for typical defects such as sink marks, flow marks and assembly gaps, ensuring mass-production consistency.
--- Project Highlights ---
1. Styling fidelity & section refinement: Based on styling CAS data, through multiple clay and A-surface refinement rounds we accurately restored design intent and optimized bumper surface sections to balance aesthetic appearance with demolding process.
2. Low-speed crash & pedestrian protection: We designed front bumper energy-absorbing blocks and rear bumper anti-collision structures to meet zero-repair low-speed crash requirements and the latest pedestrian leg/head protection regulations, reducing accident repair cost and injury risk.
3. ADAS sensor fusion: Integrating mmWave radar and ultrasonic radar mounting structures in the front bumper area, we optimized the wave-transparent window and bracket stiffness to ensure L2+ ADAS sensing signal stability.
4. Tooling support & issue resolution: Throughout tooling development, we performed CAE analysis and structural optimization for typical defects such as sink marks, flow marks and assembly gaps, ensuring mass-production consistency.