CLASS A Surfaces.

Page 1 of 45
Subject: Class-A Surface Guidelines
Contents
1) Phases of Class-A surface creation
2) Class-A surface Definition
3) Mathematical Requirements
3.1
Positional Continuity OR 0 - Order continuity
3.2
Tangent Continuity OR 1 - Order continuity
3.3
Curvature Continuity OR 2 - Order continuity
4) Curve Creation
12
17
4.1
Curve order
17
4.2
Case study for curve creation
18
4.3
Curve Redistribution
19
4.4
Creation of Symmetry Curves
20
4.5
Boundary curve creation
21
5) Surface Creation
23
5.1
Criteria for surface creation
23
5.2
Patch/Surface Parameterization
24
5.3
Patch/Face Plan
25
5.4
ISO-Curve distribution
26
5.5
Patch/Face over building and trimming of Patch/Face
27
5.6
Minimum Descriptive profile for surface creation
27
5.7
Symmetry Criteria
28
5.8
Transition Surface
29
5.9
Surface Completeness
31
5.10
Fillets
32
6) Class-A surface verification
33
6.1
Patch properties
33
6.2
Connectivity Analysis / G0 - Continuity
33
6.3
Tangency Analysis / G1-Continuity
35
6.4
Curvature Analysis
35
6.5
Reflection Analysis
36
6.6
Dynamic Highlight Analysis
36
6.7
Absolute Curvature Analysis
37
6.8
Mean Curvature Analysis
37
6.9
Maximum and Minimum Curvature Analysis
38
6.10
Guassian surface Analysis
38
Page 2 of 45

7) Curvature Analysis A case study
39
8) Summary of Class-A Surface Standards
41
8.1
Classification of components and Applicable Class-A standards
41
8.2
Class-A Standard-I
42
8.3
Class-A Standard-II
42
8.4
Class-A Standard-III
43
9) Manufacturing Criterias Case studies
44
9.1
Tips for manufacturability of hood
44
9.2
Tips for manufacturability of fender
46
9.3
Tips for manufacturability of Rear quarter panel
48
Page 3 of 45
1)
Phases of Class-A surface creation
Figure 3.1-1
Page 4 of 45
2)
Class-A surface Definition
Class-A surfaces and their requirements have a close relationship with the aesthetics of a product.
The reflection of light plays a major role in surface appearance. If a surface does not posses certain
described characteristics, Visual appearance of the product will get affected.
Characteristics of Class-A surface can be classified into three major categories
Visual Characteristics
a)
Aesthetic requirements
b)
Reflection, smoothness
c)
Style features as intended by Designer/Stylist
Mathematical Requirements
d)
0 order continuity (Positional Continuity / G0 Continuity)
e)
1 order continuity (Tangent Continuity / G1 Continuity)
f)
2 order continuity (Curvature Continuity/ G2 Continuity)
g)
3 order continuity (Constant rate of change of curvature/ G3 Continuity)
Manufacturing requirements
h)
Panels should retain their shape - proper stretching requirement should be taken care,
i)
Styled features should retain intended shapes,
j)
Feature lines like shoulder line or waist line on body side panel, feature lines on hood
panel should retain their place (skidding),
k)
Bulge effect on flange lines should be avoided,
l)
Manufacturability of shapes (Forming of sheet metal, Moulded components) etc.
Page 5 of 45

Defects which do not qualify for Class-A surface requirements
Common visual defects, which can be attributed to the bad appearance of the surfaces
m)
Broken reflection lines - which will affect the homogeneous looks of the car body,
n)
Unintended highlights ( Unequal/Non parallel)
o)
Non-uniform transition highlights,
p)
Underflush and Overflush conditions
q)
Local dark spots in the middle of smooth surface - which may result in visual mismatch of
colour,
r)
Effect of transparent surfaces like windshield, window glasses and long lenses on surface
Curvatures,
s)
Local bright -unintended highlights, spots etc.
Common Mathematical defects found in surfaces

t)
Connectivity problems like gap and overlapping along common edge,
u)
Tangency problem between two adjacent surfaces along common edge,
v)
Curvature discontinuities between surfaces,
w)
Bad parameterization,
x)
Bad distribution of ISO-parametric curves,
y)
Topological problems,
z)
Twisted patches,
aa)
Local depressions and bumps,
bb)
Triangular patches, etc.
Common Manufacturing defects found in surfaces

For sheet metal panels
cc)
Flat surface inadequate lensings,
dd)
Possibility of skid marks,
ee)
Bulge at flange lines,
ff)
Sharp, acute trim lines and shut lines,
gg)
Draw depth and corner radii mismatch,
hh)
Under flush and Over flush co-ordination,
ii)
Local depressions and bumps etc.
For Plastic components

jj)
Shrinkage marks,
kk)
Molding direction,
ll)
Undercuts,
mm) Seen parting lines,

nn)
Insufficient draft angle for given textures,
oo)
Inadequate lensing,
pp)
Warping etc.
Page 6 of 45
3)
Mathematical Requirements
3.1 Positional Continuity OR 0 - Order continuity
Surface are said to be having Positional Continuity, when they posses the following
characteristics
Adjacent faces/surfaces are sharing a common edge,
Gap between them is less or equal to the recommended tolerance limit along the common
edge
They are curvature continuous within

Refer images for more information
Surfaces are smooth

Note:
1)
Observe the smooth variation in reflection of light.
2)
Observe the presence of sharp reflection line in the
middle of the surface
Image 3.1-1
Sharing Common edge
Image 3.1-2
Page 7 of 45
Curvature Continuous within
Share a common edge
Gap between them along the edge is within

tolerance limit
Note:
Angle between the Normals to the surface or
curve on a point laying on the common edge
is not within the set tolerance limit.
Image 3.1-3
Dynamic reflection highlights Analysis Result

Note the broken Highlights at Common edge
Image 3.1-4
Mean Curvature Analysis result
Image 3.1-5
Page 8 of 45
Refer images below for allowable errors for acceptance of surface for Positional continuity
Image 3.1-6
Industry Standard Examples
DCX
Value
0.02
GM
0.025
FORD
BERTONE
0.02
0.01
TTL
0.01
Note: Some values given here are based on the inputs

from un-official source
Image 3.1-7
3.2 Tangent Continuity OR 1 - Order continuity
Surface are said to be having Tangent Continuity, when they posses the following
characteristics.
Adjacent faces/surfaces are sharing a common edge.
Gap between them is less or equal to the recommended value along the common
edge.
Angle between the normals at any common point on common edge is within in the set
tolerance value.
They are curvature continuous within.
Refer below images for more information
Page 9 of 45
Surfaces are smooth

Note:
1) Observe the smooth variation in reflection
of light.
2) Observe the absence of sharp reflection
line in the middle of the surface in
comparison with Figure for G0 continuity.
Image 3.2-8
Sharing Common edge
Image 3.2-9
Gap between them is within the

recommended tolerance limit
Share a common edge
Note:
Angle between the normals to the surface or
curve at a point laying on the common edge is
within in the set tolerance value..
Observe the sudden change in curvature value
between the normals to the surface or curve at a
point laying on the common edge.
Image 3.2-10
Page 10 of 45
Note the abrupt deviation in highlights at

Common edge.
Image 3.2-11
Image 3.2-12
Refer image below for allowable errors for acceptance of surface for Tangent continuity

DCX
Value
0.05
GM
0.05
FORD
BERTONE
0.07
0.1
TTL
0.05

Image 3.2-13
Page 11 of 45
3.3 Curvature Continuity OR 2 - Order continuity

Surface are said to be having Curvature Continuity, when they posses the following characteristics.
qq)
Adjacent faces/surfaces are sharing a common edge.
rr)
Gap between them is less or equal to the recommended value along the common edge.
ss)
Angle between the normals at any common point on common edge is within in the set
tolerance value.
tt)
Variation in curvature value at two points on same curve on surface is within specified
value.
uu)
They are curvature continuous within.
Surfaces are smooth

Note:
1) Observe the smooth variation in reflection
of light.
2) Observe the uniform dispersion of light in

the reflection zone in the middle of the
surface in comparison with Figure for G1
continuity.
Image 3.3-14
Sharing Common edge
Image 3.3-15
Page 12 of 45
1) Curvature Continuous within

2) Gap between them is within in the
tolerance limit
3) Share a common edge
Note:
Angle between the normals to the surface or
curve at a point laying on the common edge
is within the set tolerance value.
Image 3.3-16

Note the smooth deviation in highlights at Common
edge
Image 3.3-17
Image 3.3-18
Page 13 of 45
Refer image below for allowable errors for acceptance of surface for curvature continuity

Value
DCX
GM
FORD
BERTONE
0.001
0.001
0.005
0.01
TTL
0.001

Image 3.3-19
Constant Rate of Change of Curvature Continuity OR 3 - Order continuity
Surface are said to be having Constant rate of change of curvature Continuity, when they posses the
following characteristics
Adjacent faces/surfaces are sharing a common edge,
Gap between them is less or equal to the recommended value along the common edge
Angle between the normals at any common point on common edge is within in the set tolerance
value.
Variation in curvature value at two points on same curve on surface is within specified value.
Distant between two points on curves for which the change of curvature occurs has to be same
for all point on the curves.
Surfaces are smooth

Note:
1) Observe the smooth variation in reflection of light.
2) Observe the further improvement in uniform
dispersion of light in the reflection zone in the
middle of the surface in comparison with Figure for
G2 continuity.
Image 3.3-20
Page 14 of 45
Sharing Common edge
Image 3.3-21
Gap between them is within the set tolerance

value
Share a common edge
Note:
Distance between points on curve on the surface For
which curvature changes is constant
Image 3.3-22
Note the smooth deviation in highlights at

Common edge
Image 3.3-23
Page 15 of 45
Image 3.3-24
Page 16 of 45
4)
Curve Creation
Creation of a curve plays a very important role in the process of Class-A surface creation. The quality
of the curve dictates the quality of the surface.
Criteria for curve creation
Curves should be of minimum required order as far as possible (preferred order-3 maximum
order is based on the software being used)
Curves should support or facilitate the adjacent curve nature
Avoid curve with inflection unless they are a must
Split the curve as far as possible to avoid unnecessary tension
Give a close look to curve descriptors while creating curves
4.1 Curve order

Every curve has a degree - a mathematical concept referring to the degree of the polynomial that
defines the curve. The degree is generally one less than the number of points in the curve descriptor.
For this reason, you cannot have a curve with lesser points than the degree of the curve.
A higher degree curve is stiffer, in the sense that you have to move its poles a long way to produce
any appreciable change in the shape of the curve. Lower degree curves are more pliable, and tend to
follow their poles much more closely. However, it is recommended to use curves of degree 3.
Higher degree curves are more likely to contain undesirable oscillations. You should use lower degree
curves whenever possible (3, 4, and 5). Use the default degree of three (3) unless you have some
good reason for doing otherwise. The degree of a single segment curve is dependent on the number
of its specified points.
Curve of Degree 3, and Class 4

Note:
Curves of this type are easier to handle; for any
change made to the curve by moving its pole, the
change in shape will be monotonic in nature across
the curve.
Image 4.1-25
Page 17 of 45

Note:
Curves of this type are not easier to handle; for any
change made to the curve by moving its pole, the
change in shape may not be monotonic in nature
across the curve because of high parameterisation of
the curve.
Shape of the curve is exactly similar in shape and
size to the curve shown in the image.
Image 4.1-26

Note:
Shape of the curve is exactly similar in shape
and size to the curve shown in Image 4.1 -25
and Image 4.1 -26 on page No. 16
Observe the bad parameterisation of the curve,
which is not desirable for Class-A surface
creation.
Image 4.1-27
4.2 Case study for curve creation

While creating a curve from digitised points, it is essential to give a close look to the parameter
distribution of the curve.
In the given example, even though curves are exactly similar in shape, size and position they are not
identical in their mathematical properties.
Curve Degree 7, Class 8
Note:
Observe the curve parameter distribution, which
is erratic.
Curve is of very high degree and class, which is
not recommended.
Observe the adulations in curvature variation as
seen from the curvature normals.
Image 4.2-28
Page 18 of 45

Curve Degree 3, Class 4
Note:
Smooth variation in curve parameter distribution.
Desired shape is achieved by a curve of lower
degree and class, which is highly recommended.
Observe the curvature variation as seen from
the curvature normals. The variation in this case
is smooth as compared to the earlier case.
Image 4.2-29
4.3 Curve Redistribution
Curve of Degree 9 and Class 10

Note:
Observe highly haphazard distribution of curve
parameters.
Curve created by software tool from digitized
data.
Image 4.3-30
Curve of Degree 9 and Class 10

Note:
Observe smooth and monotonic variation in
distribution of curve parameters
Curve created by using
smoothing technique.
Image 4.3-31
optimization
and
Page 19 of 45
Curvature analysis of the Curve
Image 4.3-32
4.4 Creation of Symmetry Curves

For curves, which are to be used in creating surfaces for panels like Hood, Windshield, Roof,
Trunk lid and Front and rear bumpers, special care has to be taken while creating the curves
and surfaces.
While creating symmetry curves check the following properties in the curve
2)
Curvature continuity value at the plane of symmetry should be Zero
3)
Tangency continuity at plane of symmetry should be Zero
4)
Positional continuity at plane of symmetry should be Zero
5)
It is recommended to have curves of Degree 3,5 and Class 4,6
6)
It is not recommended to have a curve node at plane of symmetry.
Symmetry Curve
Note:
Observe the absence of curve node at plane of
symmetry, most of the times this condition
automatically ensures G0, G1 and G2 continuity.
Figure 4.4-2
4.5 Boundary curve creation

While creating end boundary curve for patches, check for the following characteristics in the curves.
Both curves should be of
Same class and degree
Similar nature in mathematical parameterisation.
Change in curve parameter distribution should be monotonic in nature. In the absence of above
characteristics, chances of internal surface distortions are very high.
Page 20 of 45
End boundary curves

Note:
Observe polynomial distribution of the curves.
Image 4.5-33
End boundary curves

Note:
Observe the change in the polynomial
distribution of the curves and the change in the
curve position due to this.
Image 4.5-34
Page 21 of 45
5)
Surface Creation
As explained in the earlier chapter, quality of the surface plays major role in aesthetics of the product,
it is very important we take a lot of care while creating a surface. Apart from basic requirements like
positional continuity, tangent continuity and curvature continuity, following criterias has to be given due
consideration.
5.1 Criteria for surface creation

Patch/Surface parameterisation
Polynomial representation of a surface is defined by a network of lines and points, These control
points or poles are distributed over sections.
Patch/Face Plan
Division or splitting of patches to create features in surfaces
ISO-curve distribution
Surface over-building and trimming of surface
Creation of extra surface beyond the required area for component design
Minimum descriptive profiles for surface creation

Use minimum required number of end boundaries and internal support profiles to define a patch
or surface.
Symmetry criteria
Guidelines for creation of symmetric surfaces.
Transition surface creation

Joining of two main surfaces with another surface.
Surface or face tension

High concentration of patch descriptors in a local area of a patch/face, because of maximum
curvature.
Surface completeness
Completely defined surface in all respects, by mathematical definitions.
Fillets
Page 22 of 45
5.2 Patch/Surface Parameterization

Patch or surface is said to be of good quality when it has the following characteristics
a)
Good distribution of patch descriptors or vertices
b)
Patch should not possess any kinks in the descriptors pattern.
c)
Minimum number of descriptors
d)
Uniform variation in descriptor pattern
Refer Images for more information
Good patch/face descriptors

Note:
Minimum
number
descriptors.
of
patch
Smooth variation in light reflection

on the shape.
Image 5.2-35
Bad patch/Face descriptors

Note :
High number of patch descriptors.
Kink in one of the descriptors.
Image 5.2-36
Page 23 of 45

Patch/Face Plan
Important aspect of good surface creation is patch plan. It is important for the surface creator
to plan the patch/face split to achieve good quality in surfaces. Good patch/face plan goes a
long way in helping creation of good merging of main surfaces, creation of features, termination
of features, corners, transition surfaces, bends etc. only experience can help in deciding
patch/face plan
Refer Images for more information
Shaded image of fender
Image 5.2-37
Patch/Face plan of fender
Image 5.2-38
Page 24 of 45
5.3 ISO-Parametric Curve distribution

Distribution of ISO-curves is the primary indication of a good quality patch.
Bad ISO-curve distribution

Note:
Distribution of ISO-Parametric curves is not
homogeneous
May have local surface tension.
Smooth variation is not there. Curves are bent
and Curves are straight.
Image 5.3-39
Good ISO-curve distribution

Note:
Smooth variation
distribution
in
ISO-Parametric
curve
Image 5.3-40
Difference between good and bad ISO-curve

distribution of patch/face
Note:
Path with Bad ISO-parametric curve distribution is shown in
dotted lines.
Observe the difference in shorter boundary condition
between two patches
Image 5.3-41
Page 25 of 45

5.4 Patch/Face over building and trimming of Patch/Face
5.5 Minimum Descriptive profile for surface creation
While creating a patch, use minimum required number of end boundaries and internal support
profiles to define a face or patch. Try to create the main patches bigger than required area,
Later trim them to a desired shape using trimming profiles.
Note:
e)
Use of high number of profile to define the patch may result in bad quality.
f)
Patch with minimum number of constraints posses characteristics like, good distribution
of ISO-parametric curves, Better parameterization.
Refer image for more information

Defining profiles
Patch over
building
Trimming profiles
Image 5.5-42
Page 26 of 45
5.6 Symmetry Criteria

While creating surface for Hood panel, Roof, Trunk lid , windshield, Rear window and tailgate,
normal practice is to create one side of the panel, for other side surface is reflected.
While doing so, following criteria should be fulfilled at plane of symmetry (XOZ-Plane,Y=0)
g)
h)
i)
j)
Positional Continuity
Tangency and curvature continuity
Curvature variation
No directional variation
Symmetry Plane
Curvature of good symmetry patch

Note:
In this case Positional, Tangency, and
curvature continuities are fulfilled.
Observe the length and shape variation of
curvature normal in the marked area.
Image 5.6-43
Symmetry Plane
Curvature of bad symmetry patch
Note:
In this case only Positional and Tangency
continuities are fulfilled.
Observe the length and shape variation of
curvature normal in the marked area.
Image 5.6-44
Page 27 of 45
5.7 Transition Surface

Case study for the use of transition surface and its advantages
Front fascia with transition surface
Front fascia without transition surface

Figure 5.7-3
M
T
C
Observe
Two main surfaces marked M are joined by using
transition surface marked C
Two main corner surfaces marked C are joined by using
transition surface marked T
Observe
Concept of using transition surfaces is not applied while
creating the surface
Figure 5.7-4
Uniform
Irregular
Page 28 of 45

Observe
Uniform distribution of ISO-curves between main surface
and transition surfaces.
This is the result of using a transition surface, which gives
more control over creating corner and joining surfaces.
Observe
Irregular distribution of ISO-curves in main surface.
Figure 5.7-5
Observe
Uniform variation in ISO-curve shapes.
Synergy in variation of gaps between ISO-curves
distribution.
Observe
Irregular variation in ISO-curve shapes.
Irregular variation of gaps between ISO-curves distribution.
Figure 5.7-6
Page 29 of 45
5.8 Surface Completeness

Surface should be complete in all respects.
Check for the following imperfections like incomplete filleting operation, untrimmed patches, undefined
corners, etc.
Refer images for further reference:
Observe untrimmed bottom patch
Untrimmed patch
Figure 5.8-7
Observe marked area
Incomplete
Fillet
corner
and
Figure 5.8-8
Page 30 of 45
5.9 Fillets
While creating fillets for joining two surfaces/patches, avoid using circular / cylindrical fillets.
This kind of fillets, will not guarantee a good reflection effect because of the sudden change in
curvature at the joining lines.
To improve the aesthetic effects, it is suggested to use conical blending, which is available in
softwares like CATIA and EUCLID-3.
Limit the use of mechanical blending to following areas
1)
Unseen areas like corners, Flange line blending, Joggles on flanges etc.
2)
Less important areas, like where fillet radius required R is < 5.
Mechanical Filleting
Image 5.9-45
Conical Filleting
Conical Filleting
Image 5.9-46
Page 31 of 45
6)
Class-A surface verification

6.1 Patch properties
ISO-parametric Curve distribution/Patch

parameterization
Polynomial representation of a
surface, defined by a network of
lines and points, called control
points or poles. These points are
distributed over sections.
Image 6.1-47
6.2 Connectivity Analysis / G0 - Continuity
Global connectivity analysis

This method is used for finding out the gaps in
surface topology connections.
Connectivity analysis result for hood surface is
shown in following images.
Image 6.2-48
Page 32 of 45
Green
lines

Wire frame model of the hood surface, shown
before submitting for connectivity analysis
Note:
Observe green lines in surface
Image 6.2-49
Green lines
Result of connectivity analysis
Red lines
Gaps more than 0.05 are shown in

red colour
Gaps less than 0.05 and free edges
are still shown in green colour.
Note:
1)
Threshold value for connectivity

analysis used in this case is
0.05.
2)
Method of result display

software dependent.
is
Image 6.2-50
6.3 Tangency Analysis / G1-Continuity

Global Tangency Analysis
This method is used for finding angle between
two adjacent patch along a common edge.
Note:
1)
Threshold value for connectivity analysis

used in this case is 0.05.
2)
Observe magenta coloured lines in surface.
3)
Method of
dependent.
Image 6.3-51
result
display
is
software
Page 33 of 45

6.4 Curvature Analysis
Surface/Patch curvature analysis of a curve
Laying on a surface for uniform variation in
curvature
Note:
Curvature analysis of roof is shown.
Image 6.4-52
6.5 Reflection Analysis
Display of the reflection lines created on a patch by

a line of light of infinite length
Image 6.5-53
6.6 Dynamic Highlight Analysis

This action is used to detect local flaws on supporting surfaces and to check that surfaces are smooth.
Highlights are similar to reflection lines with the difference that highlights do not depend on the user's
view point. It is a simplified reflection model. As with reflection lines, highlights magnify discontinuities
on a supporting surface.Tangent plane discontinuity between two patches in a surface is shown up as
discontinuous highlights. Discontinuous highlight tangents shows curvature discontinuity between two
patches (sharp angle where the contours join). Highlights have a lower order of continuity than the
surfaces they are traced on.
Display of the Dynamic Highlights created on a roof

surface
Page 34 of 45

Image 6.6-54
6.7 Absolute Curvature Analysis
It is used to detect the surface areas where the

surface is locally almost flat, that is when the
absolute curvature is almost null.
Image 6.7-55
6.8 Mean Curvature Analysis
The utmost values appear where the surface is the

most warped. Mean is largely used to detect
irregularities on the surface. A minimal surface is
characterized by a null mean
curvature.
Image 6.8-56
6.9 Maximum and Minimum Curvature Analysis
The geometric construction of main curvatures is

the following: let be a plane containing the normal to
the surface in a given point. This plane cuts the
surface along a curve that has
a given curvature in this point. If this plane rotates
around the normal, the curvatures of the curves of
intersection with the surface will vary between two
utmost values. These two values are the main
curvatures
Image 6.9-57
6.10 Guassian surface Analysis

It describes the local shape of a surface in one point:
Page 35 of 45

If it is positive, the point is elliptic, i.e. the surface has locally the shape of an ellipsoid around the point.
If it is negative, the surface is hyperbolic in this point, i.e. the local shape is a horse saddle. If it is null,
the surface is parabolic in this point, i.e. one of the two main curvatures is null in this point.
Ps: The cone and the cylinder are two surfaces where all points are parabolic.
Local depression on a roof surface Shown using

Guassian surface analysis
Image 6.10-58
7)
Curvature Analysis A case study
Good roof surface

Observe
Smoothness of surface
Uniform Dispersion of light in reflection zone
Defective roof surface

Observe
Smoothness of surface
Uniform Dispersion of light in reflection zone
Image 6.10-59
Page 36 of 45

Good roof surface
Observe
Smoothness of Dynamic highlights
Uniform variation in dynamic highlight line shapes
Uniform Gap between dynamic highlight lines

Observe
Smoothness of Dynamic highlights
Uniform variation in dynamic highlight line shapes
Non-uniform Gap between dynamic highlight lines
Image 6.10-60
Good roof surface

Mean curvature analysis result

Mean curvature analysis result
Image 6.10-61
Good roof surface

Observe absence of local depression in
Guassian curvature analysis result

Observe presence of local depression in
Guassian curvature analysis result
Image 6.10-62
Page 37 of 45
8)
Summary of Class-A Surface Standards

8.1 Classification of components and Applicable Class-A standards
SHEET METAL PANELS
External Panels
Internal Panel
External Seen
External Unseen
Internal Seen
Internal Unseen
Class A Standard I
Class A Standard II
Class A Standard II
Class A Standard III
Figure 8.1-9
Plastic Trims
External Panels
Internal Panel
Painted/Textured Seen
Painted/Textured Unseen
Painted/Textured Seen
PaintedTextured Unseen
Class A Standard I
Class A Standard II
Class A Standard II
Class A Standard III
Figure 8.1-10
Page 38 of 45
8.2 Class-A Standard-I

Applicable For
Characteristics
1) External seen Sheet metal

panels
2) Exterior seen painted
plastic trims
Standards
G0 Positional Continuity
0.01
G1 Tangency Continuity
0.05
G2 Curvature Continuity
0.001
G3 Constant rate of changes of curvature
---
Patch descriptors
Refer Section 5.2
Refer Section 5.4
Fillets
Mechanical Fillets for < 5R *
Manufacturability criterias
Refer Section 9
Dynamic highlights
Refer Section 6.6

Table 8-1
8.3 Class-A Standard-II

Applicable For
1) Exterior
seen
textured trims
2) Interior
seen
textured trims
3) Interior
seen
textured trims
4) Interior seen sheet
panels
Characteristics
plastic
plastic
plastic
metal
Standards
0.02
0.05
0.02
Patch descriptors
Refer Section 5.2
Refer Section 5.4
Fillets
Refer Section 9
Dynamic highlights
Refer Section 6.6

Table 8-2
Page 39 of 45
8.4 Class-A Standard-III

Applicable For
1) External unseen areas of
Sheet metal panels
Example: Areas of Body
side panel hidden after
door closer, Lamp
pockets, Mirror pockets on
door frame, Etc.
2) Unseen
painted
and
textured plastic trims
Characteristics
Standards
0.02
0.1
0.05
Patch descriptors
Refer Section 5.2
Refer Section 5.4
Fillets
Refer Section 9
Dynamic highlights
Refer Section 6.6
Note:
3)
Take care for not changing styling intent shapes and features in all above cases.
4)
Seen means - areas which are coming in lines of direct visual angle of a person standing next
to the car, and sitting inside the car.
5)
Unseen means - areas which are not coming in lines of direct visual angle of a person standing
next to the car, and sitting inside the car.
6)
* In case of fillet values take care for minimum exterior and interior projection regulations.
7)
Decide the maximum allowed deviation for Class-A surface creation from Digitised data for each
model.
8)
Take the approval from Styling department in case of deviation from digitized data.
9)
Observe for regulatory requirements during the creation of Class-A surfaces.

Example: Minimum external and internal projection regulations.
10)
At the stage of design verification, changes done on styled surface with respect to the Stylingfreeze should be documented and agreed upon.
Page 40 of 45
9)
Manufacturing Criterias Case studies
Objective of this section is to lead stylist or product engineers through the manufacturing process for
sheet metal. Cases listed in this section of the documents are only for reference and knowledge of the
stylist and product engineers. The cases explained here are not to be considered as guidelines.
While designing the panels for manufacturability, proper attention needs to be given for following
aspects of sheet metal components.
Panels should retain their shape after stamping process, for the same proper stretching requirement
should be taken care, Styled features should retain intended shapes, For example, Feature lines like
shoulder line or waist line on body side panel, Feature lines on hood panel should retain their place.
Bulge effect on flange lines should be avoided.
In the same way, while designing plastic trims, care should be taken care to avoid warping of panels at
free ends, shrinkage effect on the areas where internal ribs are provided for strength purpose.
9.1 Tips for manufacturability of hood
Shaded image of hood panel

Image 9.1-63
Page 41 of 45
Figure 9.1-11
Page 42 of 45
9.2 Tips for manufacturability of fender
Shaded Image of Front fender Left

Image 9.2-64
Page 43 of 45
d
D
In depth D is not constant, give constant offset

depth d to avoid bulge effect along flange line
Indicator Lamp depression depth to be kept

within 2-3 mm
50R Minimum
Radius to be kept
Incase of radical under sweeping at rear of wheel

arch, Reduce the flange with to minimum possible
Feature line near wheel arch, high risk of skidding,

if the panel is stretched to the maximum limit
Figure 9.2-12
9.3 Tips for manufacturability of Rear quarter panel

Keep the feature line away from flange line by
minimum 25mm, to avoid skidding effect.
Do not leave the feature line sharp for avoiding

local stretching, on the fillet. Complete them by
using conical filleting option with maximum
possible ratio
Flange Line
Minimum angle suggested between the
two surfaces creating this kind of feature is 20
Figure 9.3-13
Page 44 of 45
Figure 9.3-14
Page 45 of 45
Figure 9.3-15

CLASS A Surfaces.

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Page 1 of 45

Subject: Class-A Surface Guidelines

2) Class-A surface Definition

Positional Continuity OR 0 - Order continuity

Tangent Continuity OR 1 - Order continuity

Curvature Continuity OR 2 - Order continuity

Case study for curve creation

Creation of Symmetry Curves

Boundary curve creation

Criteria for surface creation

Patch/Face over building and trimming of Patch/Face

Minimum Descriptive profile for surface creation

6) Class-A surface verification

Connectivity Analysis / G0 - Continuity

Tangency Analysis / G1-Continuity

Dynamic Highlight Analysis

Absolute Curvature Analysis

Mean Curvature Analysis

Maximum and Minimum Curvature Analysis

Guassian surface Analysis

Subject: Class-A Surface Guidelines

8) Summary of Class-A Surface Standards

Classification of components and Applicable Class-A standards

9) Manufacturing Criterias Case studies

Tips for manufacturability of hood

Tips for manufacturability of fender

Tips for manufacturability of Rear quarter panel

Subject: Class-A Surface Guidelines

Phases of Class-A surface creation

Subject: Class-A Surface Guidelines

Class-A surface Definition

Style features as intended by Designer/Stylist

0 order continuity (Positional Continuity / G0 Continuity)

1 order continuity (Tangent Continuity / G1 Continuity)

2 order continuity (Curvature Continuity/ G2 Continuity)

3 order continuity (Constant rate of change of curvature/ G3 Continuity)

Styled features should retain intended shapes,

Bulge effect on flange lines should be avoided,

Manufacturability of shapes (Forming of sheet metal, Moulded components) etc.

Subject: Class-A Surface Guidelines

Unintended highlights ( Unequal/Non parallel)

Non-uniform transition highlights,

Underflush and Overflush conditions

Local bright -unintended highlights, spots etc.

Common Mathematical defects found in surfaces

Connectivity problems like gap and overlapping along common edge,

Tangency problem between two adjacent surfaces along common edge,

Curvature discontinuities between surfaces,

Bad distribution of ISO-parametric curves,

Local depressions and bumps,

Triangular patches, etc.

Common Manufacturing defects found in surfaces

Flat surface inadequate lensings,

Possibility of skid marks,

Bulge at flange lines,

Sharp, acute trim lines and shut lines,

Draw depth and corner radii mismatch,

Under flush and Over flush co-ordination,

Local depressions and bumps etc.

For Plastic components

mm) Seen parting lines,

Insufficient draft angle for given textures,

Subject: Class-A Surface Guidelines

Adjacent faces/surfaces are sharing a common edge,