Full Vehicle | Optimal Inc. | Engineering for Electrification & Lightweighting

Vehicle Design & Development

Exterior, Interior & Packaging

follow url Optimal works with different CAD software packages to develop, design and engineer interiors.  Starting from Studio design sketches optimal can develop surfaces, part breakups, bill of materials, and recommend materials for a world class interior that every driver and passenger are looking to experience.

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Using information developed from our packaging studies we can establish ergonomically friend features and functions that are easy to find and reach conveniently throughout the vehicle. With our extensive benchmarking and teardowns of competitive vehicles we are always trying to find the voice of the customer and looking for continuous improvements in the smallest details. Some key elements captured are:

  • Design of seats, consoles, side trim, instrument panels, headliner system, Safety systems
  • Engineering, Bill of materials and material selection
  • Dimensional control, fit and finish, and tolerancing

Tastylia Buy 20 MG Optimal works with different CAD software packages to develop, design and engineer interiors.  Starting from Studio design sketches optimal can develop surfaces, part breakups, bill of materials, and recommend materials for a world class interior that every driver and passenger are looking to experience. Using information developed from our packaging studies we can establish ergonomically friend features and functions that are easy to find and reach conveniently throughout the vehicle.

Vehicle Exterior and Interior Trim Vehicle Exterior and Interior Trim

With our extensive benchmarking and teardowns of competitive vehicles we are always trying to find the voice of the customer and looking for continuous improvements in the smallest details. Some key elements captured are:

  • Design of seats, consoles, side trim, instrument panels, headliner system, Safety systems
  • Engineering, Bill of materials and material selection
  • Dimensional control, fit and finish, and tolerancing

Vehicle Exterior and Interior Trim

Optimal has the tools and knowledge for all vehicle and occupant packaging needs, including Catia and CAVA software. SAE standards are used to set targets and create the environment most desired by the customer.  Optimal performs continuous trade off studies to improve the design throughout the design process.

  • SAE Mankins in the most comfortable seating position according to the vehicle architecture,
  • Reach zones and other ergonomic zones are created based on SAE standards and benchmarking/target setting
  • Interior and Exterior Vision Analysis using multiple countries’ specifications/requirements/regulations
  • Seating Package drawings with dimensions

Vehicle Packaging Vehicle Packaging Vehicle Packaging

Optimal’s experienced engineers can develop a full exterior trim package including front end systems that satisfy global pedestrian impact protection requirements. Development of advanced exterior lighting designs using cutting edge technologies that incorporate unique styling elements. Vehicle Exterior Trim

  • Exterior trim development for fascias, sill & roof moldings and wheel liners
  • Underbody shielding for maximum aerodynamic performance including CFD modelling
  • Exterior mirror systems, water management and washer systems

Optimal has experience developing a prototype of infotainment system including driver cluster and center fascia. Optimal provides a comprehensive service in the following areas:

  • Functional architecture benchmarking of premium vehicles
  • UI/UX designing of driver cluster and center fascia
  • Prototyping of infotainment system for show car or product intended car

Structural Optimization—Optimal has been a pioneer in weight optimization for vehicles well before the term “Lightweighting” became a corporate mission. As the auto industry and other transportation sectors become increasingly motivated to building vehicles that are less heavy as a way to achieve better fuel efficiency and reduce emissions, Optimal has proved to be a critical partner for structural optimization. Enlarge Image + Optimal offers unique topological and zero base weight analysis to reduce mass in vehicles and components while balancing both the structural integrity and cost of the component.

  • Body-in-White (BIW)
  • Front/Rear Ends, Bumpers, Crash Cans
  • Body Closures
  • Subframe, Arm, Link/Bar
  • Exterior Trim

Engineering Optimization of BIW Image Lightweighting Image

NVH (Noise, Vibration, and Harshness) Analysis Services

Optimal has the ability to analytically perform component and full product NVH analysis. Mapping the excitation source, transmission path, and responding system, FEA modal analysis is implemented to identify opportunities to move, change or eliminate causes of NVH issues.

NVH (Noise Vibration & Harshness)
  • Acoustics
  • Vibrations
  • Modal Analysis / Alignments
  • Frequency Response Analysis

Since 1986, Optimal, Inc. has been one of the most experienced and innovative engineering service suppliers in the world.  We offer a variety of services including the highest quality CAE services, Reverse Engineering, Analytical Benchmarking, Manufacturing Services, as well as complete Product Development solutions. Our multi-industry experience and knowledge-base brings all the advantages and tools necessary to significantly reduce your product development costs, and improve your product performance and competitiveness. We don’t just deliver what is asked, we use our unique perspective of multi-industry insight and processes to help share and recommend the best industry solutions for you. Optimal develops many innovative methods and provides comprehensive Engineering Services for the entire product development cycle to create “optimal” design solutions.

Optimal CAE offers a full spectrum of CAE Services

Optimal CAE - computer aided engineering services

Body & Chassis

Optimal can support the development of lightweight, high performance body and closure structures utilizing advanced material strategies and joining methodologies. Utilizing our significant experience, Optimal can develop the structure to meet exacting structural requirements while simultaneously ensuring dimensional control and lean manufacturing processes are incorporated.

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  • Advanced lightweight aluminum or mixed material construction
  • Optimized aluminum extrusion, high pressure die casting and sheet stamping mix
  • Ultra high strength steel and third-generation Advanced High Strength Steel to meet safety requirements efficiently
  • Strategies for dissimilar material joints to manage galvanic corrosion & material expansion differentials
  • Optimized structural concept for electric platforms to maximize battery packaging space
  • Concept development to production release

Power System Adaptation & Vehicle Control

Optimal’s staff includes veterans of industry with deep expertise in developing vehicle controls for body, chassis, and assisted driving.

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Vehicle Body Controls

  • Vehicle body controller (BCU) requirements analysis and specification
  • Electric system design and verification
    • Lightings control
    • Accessory subsystems integration
    • Security systems
    • Infotainment systems
  • Dynamic Chassis Controls
    • Brake control
      • ABS, TCS
      • ESC
      • System development
        • Hardware specification and supplier recommendation
          • VCU and signal interface
          • Vehicle controls integration
        • Control algorithm design and validation
      • Steering control
        • EPS
          • Vehicle and subsystem requirements analysis
          • Hardware specification and supplier recommendation
            • VCU and signal interface
            • Vehicle controls integration
          • Control algorithm design and validation

Intelligent Vehicle Controls, Assisted and Autonomous Driving

  • System requirements analysis and architectural design
    • VCU and signal interface
    • Vehicle controls integration
  • By-wire vehicle control
    • Brake by wire
    • Acceleration by wire
    • Steering by wire
  • Environmental perception
    • Radar
    • Camera
    • AI and data fusion
  • System analysis, design, verification and validation
    • MIL, SIL, HIL, VIL, DIL
  • Limited high-way autonomous driving systems
  • Driver assistance (ADAS)
    • Blind-spot warning
    • Collision warning
    • Automated parking assistance
    • AEB
    • ACC
  • Prototype vehicle build

Lightweighting

Structural Optimization—Optimal has been a pioneer in weight optimization for vehicles well before the term “Lightweighting” became a corporate mission. As the auto industry and other transportation sectors become increasingly motivated to building vehicles that are less heavy as a way to achieve better fuel efficiency and reduce emissions, Optimal has proved to be a critical partner for structural optimization.

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Enlarge Image + Optimal offers unique topological and zero base weight analysis to reduce mass in vehicles and components while balancing both the structural integrity and cost of the component.

  • Body-in-White (BIW)
  • Front/Rear Ends, Bumpers, Crash Cans
  • Body Closures
  • Subframe, Arm, Link/Bar
  • Exterior Trim

Engineering Optimization of BIW Image Lightweighting Image

Electrical System Integration

Optimal has the capabilities to support new electric vehicle product development process. Our team consists of well-known automotive veterans that have been involved in electric vehicle design for over 20 years. Optimal has experience in benchmarking electric vehicles as well as design and engineering of critical electric vehicle components such as vehicle control units, battery packs, battery management systems, EV drive systems. Electrification and Electrical Systems

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Electrical Vehicle Control & Powertrain Development

Optimal has experience developing:

  • Vehicle control units (VCU)
  • CAN bus decoding
  • EV powertrain performance benchmarking
  • EV drive performance testing (battery, motor, inverter)
  • EV battery pack design architecture optimized for performance, crash, NVH, safety
  • EV drive component development including motors, gearbox
  • EV powertrain optimization through CAE structural and CFD thermal management analysis
  • EV powertrain performance simulation and physical testing
  • Electrified Propulsion Systems
    • Electric propulsion
      • System requirements analysis and architectural design
        • VCU and signal interface
        • Vehicle controls integration
      • Performance EV systems
      • Economical city commuting EV systems
      • Regen braking
      • Regen blending
        • Hardware specification
        • Control algorithm design and validation
      • Hybrid propulsion
        • Range extender
      • Prototype vehicle build

ADAS & Autonomous Driving Integration

Intelligent Vehicle Controls, Assisted and Autonomous Driving

  • System requirements analysis and architectural design
    • VCU and signal interface
    • Vehicle controls integration
  • By-wire vehicle control
    • Brake by wire
    • Acceleration by wire
    • Steering by wire
  • Environmental perception
    • Radar
    • Camera
    • AI and data fusion
  • System analysis, design, verification and validation
    • MIL, SIL, HIL, VIL, DIL
  • Limited high-way autonomous driving systems
  • Driver assistance (ADAS)
    • Blind-spot warning
    • Collision warning
    • Automated parking assistance
    • AEB
    • ACC
  • Prototype vehicle build

Mule & Prototype Build

Optimal has experience developing:

  • Testbed mule electric vehicles equipped with prototype components
  • Evaluation of vehicle controls with EV powertrain
  • Design and build prototype electric vehicle for evaluation

Homologation for Crash Safety

Optimal Full Vehicle Testing Services utilize some of the industry’s most recognized equipment and software tools to provide our customers with high quality analysis that they need to evaluate competitive products or optimized their own product designs.

vehicle lightweight optimizationEnlarge Image +

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Optimal offers the following full vehicle testing services:

  • Full vehicle simulation models
  • CAE validation including aerodynamics, durability, crash, safety, NVH, CFD
  • On-Dyno or On-Road performance testing

Program Management

It starts with a number of product planning sessions with your team. Our experts join your team to define and refine requirements…

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  • We help refine customer wants, critical product features
  • We help define Vehicle Technical Specifications (VTS) based on existing and available resources
  • We help define the Bill of Materials (BOM) for the product
  • We help define the Bill of Process (BOP) for the product including cost, time, logistics
  • We help define critical supply chain partners with a focus on for long lead time items
  • We help define product development process, vehicle program plans, cost structures, and master timing schedules
  • We help define project teams, organizational structure and corresponding program team deliverables

Full Vehicle Development Product Planning

Award Winning Quality Service & Value

Through the application of the latest technology coupled with a highly experienced, trained and efficient staff, Optimal is the Engineering Services provider of choice for many companies. Optimal is the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

Optimal maintains its ISO-9001:2008, ISO-14001:2004, is a certified Minority Supplier, and is a member of the Michigan Minority Business Development Council (MMBDC). Optimal was the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

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