CLASS A Surfaces

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Subject: Class-A Surface Guidelines
Contents
1) Phases of Class-A surface creation 3
2) Class-A surface Definition 4
3) Mathematical Requirements 7
3.1 Positional Continuity OR 0 - Order continuity 7
3.2 Tangent Continuity OR 1 - Order continuity 9
3.3 Curvature Continuity OR 2 - Order continuity 12
4) Curve Creation 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
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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 Criteria’s – 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
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1) Phases of Class-A surface creation
Figure Phases of Class-A surface creation-1

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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.
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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.
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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 Positional Continuity OR 0 - Order continuity-1
Sharing Common edge

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 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.
Dynamic reflection highlights Analysis Result

Note the broken Highlights at Common edge
Mean Curvature Analysis result

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Refer images below for allowable errors for acceptance of surface for Positional continuity
Industry Standard Examples

DCX GM FORD BERTONE TTL
Value 0.02 0.025 0.02 0.01 0.01
Note: Some values given here are based on the inputs

from un-official source

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

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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 Tangent Continuity OR 1 - Order continuity-8
Sharing Common edge
 Curvature Continuous within

 Gap between them is within the
recommended tolerance limit
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.

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Note the abrupt deviation in highlights at
Common edge.

Refer image below for allowable errors for acceptance of surface for Tangent continuity

Value 0.05 0.05 0.07 0.1 0.05


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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 Curvature Continuity OR 2 - Order continuity-14
Sharing Common edge

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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.

Note the smooth deviation in highlights at Common
edge

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Refer image below for allowable errors for acceptance of surface for curvature continuity

Value 0.001 0.001 0.005 0.01 0.001


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.

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Sharing Common edge
Curvature Continuous within

 Gap between them is within the set tolerance
value
Note:
Distance between points on curve on the surface For
which curvature changes is constant

Note the smooth deviation in highlights at
Common edge

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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 Curve order-25

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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.

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

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 Case study for curve creation-28

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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 Case study for curve creation-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 Curve Redistribution -30
Curve of Degree 9 and Class 10

Note:
Observe smooth and monotonic variation in
distribution of curve parameters
Curve created by using optimization and
smoothing technique.

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Curvature analysis of the Curve

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 Creation of Symmetry Curves-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.
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End boundary curves

Note:
Observe polynomial distribution of the curves.
Image Boundary curve creation-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 Boundary curve creation-34

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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 criteria’s 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
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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 of patch
descriptors.
Smooth variation in light reflection
on the shape.
Image Patch/Surface Parameterization-35
Bad patch/Face descriptors

Note :
High number of patch descriptors.
Kink in one of the descriptors.

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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
Patch/Face plan of fender

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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 ISO-Parametric Curve distribution-39
Good ISO-curve distribution

Note:
Smooth variation in ISO-Parametric curve
distribution
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

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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 Minimum Descriptive profile for surface creation-42

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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) Positional Continuity
h) Tangency and curvature continuity
i) Curvature variation
j) 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 Symmetry Criteria-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 Symmetry Criteria-44

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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 Transition Surface-3
C M
M
Observe Observe
Two main surfaces marked “M” are joined by using Concept of using transition surfaces is not applied while
transition surface marked “C” creating the surface
Two main corner surfaces marked “C” are joined by using
transition surface marked “T”
Irregular
Uniform
ISO-curve distribution
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Observe Observe
Uniform distribution of ISO-curves between main surface Irregular distribution of ISO-curves in 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 Observe
Uniform variation in ISO-curve shapes. Irregular variation in ISO-curve shapes.
Synergy in variation of gaps between ISO-curves Irregular variation of gaps between ISO-curves distribution.
distribution.

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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 Surface Completeness-7
Observe marked area
Incomplete corner and

Fillet
Figure Surface Completeness-8
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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
software’s 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.
R
Mechanical Filleting
Image Fillets-45
Conical Filleting
Conical Filleting
Image Fillets-46
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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 Patch properties-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 Connectivity Analysis / G0 - Continuity-48

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Green
lines
Wire frame model of the hood surface, shown
before submitting for connectivity analysis
Note:
Observe green lines in surface

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 is
software dependent.

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 result display is software
dependent.
Image Tangency Analysis / G1-Continuity-51

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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 Curvature Analysis-52

6.5 Reflection Analysis
Display of the reflection lines created on a patch

by a line of light of infinite length
Image Reflection Analysis-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
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Image Dynamic Highlight Analysis-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 Absolute Curvature Analysis-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 Mean Curvature Analysis-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 Maximum and Minimum Curvature Analysis-57

6.10 Guassian surface Analysis
It describes the local shape of a surface in one point:
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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 Guassian surface Analysis-58
7) Curvature Analysis – A case study
Good roof surface Defective roof surface

Observe Observe
Smoothness of surface Smoothness of surface
Uniform Dispersion of light in reflection zone Uniform Dispersion of light in reflection zone
Image Curvature Analysis – A case study-59

Page 36 of 45

Observe Observe
Smoothness of Dynamic highlights Smoothness of Dynamic highlights
Uniform variation in dynamic highlight line shapes Uniform variation in dynamic highlight line shapes
Uniform Gap between dynamic highlight lines Non-uniform Gap between dynamic highlight lines

Mean curvature analysis result Mean curvature analysis result

Observe absence of local depression in Observe presence of local depression in
Guassian curvature analysis result Guassian curvature analysis result

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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 Classification of components and Applicable Class-A standards -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 Classification of components and Applicable Class-A standards -10

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8.2 Class-A Standard-I

Applicable For Characteristics Standards
1) External seen Sheet metal G0 – Positional Continuity 0.01
panels
G1 – Tangency Continuity 0.05
2) Exterior seen painted
plastic trims G2 – Curvature Continuity 0.001
G3 – Constant rate of changes of curvature ---
Patch descriptors Refer Section 5.2
ISO-curve distribution Refer Section 5.4
Fillets Mechanical Fillets for < 5R *
Manufacturability criteria’s Refer Section 9
Dynamic highlights Refer Section 6.6
Table Summary of Class-A Surface Standards-1

8.3 Class-A Standard-II
1) Exterior seen plastic G0 – Positional Continuity 0.02
textured trims
2) Interior seen plastic
textured trims G2 – Curvature Continuity 0.02
3) Interior seen plastic Patch descriptors Refer Section 5.2
textured trims
ISO-curve distribution Refer Section 5.4
4) Interior seen sheet metal
panels Fillets Mechanical Fillets for < 5R *
Table Summary of Class-A Surface Standards-2

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8.4 Class-A Standard-III

1) External unseen areas of G0 – Positional Continuity 0.02
Sheet metal panels
Example: Areas of Body
side panel hidden after G2 – Curvature Continuity 0.05
door closer, Lamp Patch descriptors Refer Section 5.2
pockets, Mirror pockets on
door frame, Etc. ISO-curve distribution Refer Section 5.4
2) Unseen painted and Fillets Mechanical Fillets for < 4R *
textured plastic trims
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 Styling-
freeze should be documented and agreed upon.
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9) Manufacturing Criteria’s – 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 Tips for manufacturability of hood-63

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Figure Tips for manufacturability of hood-11

Page 42 of 45
9.2 Tips for manufacturability of fender
Shaded Image of Front fender Left

Image Tips for manufacturability of fender-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

Feature line near wheel arch, high risk of skidding, arch, Reduce the flange with to minimum possible
if the panel is stretched to the maximum limit
Figure Tips for manufacturability of fender-12

9.3 Tips for manufacturability of Rear quarter panel
Keep the feature line away from flange line by Do not leave the feature line sharp for avoiding
minimum 25mm, to avoid skidding effect. 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 Tips for manufacturability of Rear quarter panel-13

Page 44 of 45

Page 45 of 45

CLASS A Surfaces

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CLASS A Surfaces

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Page 1 of 45

Subject: Class-A Surface Guidelines

2) Class-A surface Definition 4

6) Class-A surface verification 33

Subject: Class-A Surface Guidelines

7) Curvature Analysis – A case study 39

8) Summary of Class-A Surface Standards 41

9) Manufacturing Criteria’s – Case studies 44

Subject: Class-A Surface Guidelines

1) Phases of Class-A surface creation

Figure Phases of Class-A surface creation-1

Subject: Class-A Surface Guidelines

2) Class-A surface Definition

Subject: Class-A Surface Guidelines

Defects which do not qualify for Class-A surface requirements

Subject: Class-A Surface Guidelines

Refer images for more information

Surfaces are smooth

Image Positional Continuity OR 0 - Order continuity-1

Sharing Common edge

Image Positional Continuity OR 0 - Order continuity-2

Subject: Class-A Surface Guidelines

 Curvature Continuous within

Image Positional Continuity OR 0 - Order continuity-3

Dynamic reflection highlights Analysis Result

Image Positional Continuity OR 0 - Order continuity-4

Mean Curvature Analysis result

Image Positional Continuity OR 0 - Order continuity-5

Subject: Class-A Surface Guidelines

Image Positional Continuity OR 0 - Order continuity-6

Industry Standard Examples

Value 0.02 0.025 0.02 0.01 0.01

Note: Some values given here are based on the inputs

Image Positional Continuity OR 0 - Order continuity-7

Refer below images for more information

Subject: Class-A Surface Guidelines

Surfaces are smooth

Image Tangent Continuity OR 1 - Order continuity-8

Sharing Common edge

Image Tangent Continuity OR 1 - Order continuity-9

 Curvature Continuous within

Image Tangent Continuity OR 1 - Order continuity-10

Subject: Class-A Surface Guidelines

Dynamic reflection highlights Analysis Result

Image Tangent Continuity OR 1 - Order continuity-11

Mean Curvature Analysis result

Image Tangent Continuity OR 1 - Order continuity-12

Industry Standard Examples

Value 0.05 0.05 0.07 0.1 0.05

Image Tangent Continuity OR 1 - Order continuity-13

Subject: Class-A Surface Guidelines

3.3 Curvature Continuity OR 2 - Order continuity

Surfaces are smooth

Image Curvature Continuity OR 2 - Order continuity-14

Sharing Common edge

Image Curvature Continuity OR 2 - Order continuity-15

Subject: Class-A Surface Guidelines

1) Curvature Continuous within

Image Curvature Continuity OR 2 - Order continuity-16

Dynamic reflection highlights Analysis Result

Image Curvature Continuity OR 2 - Order continuity-17

Mean Curvature Analysis result

Image Curvature Continuity OR 2 - Order continuity-18