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The driver’s cab of an urban transit bus is to be modernised, by replacing the old design with a new and fresh, but still functional, design. The WEBER GmbH project team in Aschaffenburg, acting as development partner, accompanied the project manager from the first ideas to the final product, ready for series production.
The first free-form surfaces were constructed on the basis of a simple design sketch. This ongoing direct collaboration with the designer was maintained throughout the development process – from construction of the design surfaces (Class A), design validation by package studies, manufacturing feasibility and assembly analysis, through preparation of the design concept and working out of component data, to series production drawings. Various manufacturing processes for components, including injection moulding, RIM and foil foam, were investigated and evaluated in terms of cost/benefit and presented to the customer for a final decision.
Contrastingly to the design validation phase, intensive coordination with potential tool and series production suppliers took place. Kinematic analysis was used to investigate and simulate various concepts for height adjustment (pull, push designs) and functional models were produced with pneumatic and electromagnetic adjustment.