Cars

Product Development Process

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  • air-design-cad
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  • air-design-tooling
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  • air-design-personalization

DISCOVERY

Arguably the most important step of our collaboration process, discovery involves intensive listening and significant dialog.  

Beyond understanding the customer’s vision, our mutual goal is to clearly define the scope of the project, identify the appropriate resources, create schedules, and capture commitments to ensure successful implementation.  On time or early.

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CONCEPT DESIGN


A broad perception, concept design involves imagining and innovating from all angles. At Air Design, concept designers must be able to envision the whole picture, from product requirements to aesthetics to development issues. They are an integral part of the creative team, interpreting complex ideas and how they can be realized into fruition.

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CAD ENGINEERING


With a strong commitment to technology, our product development process integrates a sophisticated digital workflow.

Starting with a laser scan or vehicle CAD, our Engineering team utilizes powerful 3D Modeling software (list CAD software here) to breathe precise digital life into the desired concept.

Proudly flexible, we can work with virtually every native CAD file format available (CATIA, UG, IGES, STEP, etc.).

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ADVANCED PROTOTYPING


Imagine being able to produce instant functional prototypes for automotive parts, consumer goods, packaging, displays, and a wide variety of items with the highest quality and accuracy of an end product before actual production occurs.

Air Design's 3D visual modeling techniques combined with advanced prototyping 3D Printers and CNC machining capabilities allow engineers to create dimensionally accurate mock-products that the design team can test and further develop.


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TOOLING


In-house Tooling Design and Construction capabilities allow our OEM partners to choose from a wide variety of injection and thermoforming technologies based on the demands of each individual project.

Whether it’s 1,000 units over a lifetime or more than 50,000 units per year, we have an appropriate tooling solution to offer.

Tooling materials and options include:

  • Soft Ceramic Tooling Compounds

  • Composite Materials

  • Epoxy, Urethane, Silicon Casting

  • Aluminum / Steel Injection Tools

  • Custom Aluminum Profiles

  • Wood, Foam, and Clay Master Models

MANUFACTURING

PUR-RIM:

(Polyurethane-Reaction Injection Molding):

This technology offers exceptional design flexibility, precise dimensional detail, superb surface quality, and unbeatable durability performance at a reasonable cost.  We use ONLY best-in-class raw materials to deliver great quality and value. Highly competitive in low to medium volume applications, and ideally suited to Special Edition programs.

VACUUM FORMING:

Using TPO, high-impact ABS, and multi-layer engineering plastic sheet, our thermoforming team can pull parts as large as 51  X 98 X 26 inches

(130 X 250  X 70cm) in our dedicated vacuum forming cell.

ROBOTIC TRIMMING:

With custom cutting jigs designed and built in-house, our robots consistently meet the highest fitting standards in the automotive industry.

“Robots and humans work hand in hand, complementing each other with their respective skills.” - Kuka Roboter GmbH


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"Robots and humans work hand in hand, complementing each other with their respective skills" - Kuka Roboter GmbH.




Air Design vehicle accessories are manufactured with proprietary technology that incorporates high impact multi-layer ABS engineering plastic, encapsulated with a high-pressure polyurethane elastomer.

ABS and TPR engineering plastics-thermoforming are used for parts that require an integrated body color, stainless steel, and/or chromed finishes. They are ideal for bumper overlays, skid plates, fender flares, all kind of body appliqués, floor liners, spare tire covers and other applications. Trimming robots guarantee an accurate shape to all the parts.


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PUR-RIM (Polyurethane Reaction Molding) manufacturing technology offers the high quality and low entry cost that is essential to be competitive in the low and medium volume market. Air Design controls one of the largest PUR–RIM production facilities in North America for automotive body parts. 

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VALIDATION

Design, Manufacturing, and Quality teams converge here to prove all manufacturing aspects of the proposed component and process.  

For a project to move forward, all invested parties must concur that defined critical elements can be consistently executed within agreed tolerances.

Air Design engages numerous independent testing laboratories as necessary to formalize the validation.

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BODY COLOR PAINT

Approved by every OEM partner in our customer family, Air Design’s custom state-of-the-art paint line is designed for eco-responsible application of the most advanced water bourne paint systems available.

Our 540 foot semi-automated paint line and cure oven is specially designed for painting large exterior plastic parts such as Fascias, Spoilers, Wings, Cladding, Door Panels, Bumper Guards and Fender Flares with a capacity of two thousand parts a day. 

Air Design is seriously committed to a minimal and green footprint!

Air Design is a regional leader in vehicle personalization programs, exporting products to more than 30 countries worldwide. A recent expansion into the aftermarket via an exclusive wholesale distribution partnership with industry leader Keystone Automotive Operation Inc. allows Air Design to call upon its extensive OE experience and increase consumer access to its high-end styling products

Air Design´s state-of-the-art paint line offers OEM-approved body color premium paint solutions comprised only with the highest quality paint systems to create the most advanced topcoat finishes in the automotive industry. 

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LOGISTICS

Seamless global door-to-door service.

As an international leader in Vehicle Personalization Programs, our seasoned logistics team proudly delivers restyling and protection products to more than 30 countries worldwide.  

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Air Design is a regional leader in vehicle personalization programs, exporting products to more than 30 countries worldwide. A recent expansion into the aftermarket via an exclusive wholesale distribution partnership with industry leader Keystone Automotive Operation Inc. allows Air Design to call upon its extensive OE experience and increase consumer access to its high-end styling products. 

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VEHICLE PERSONALIZATION PROGRAMS AT VP CENTER

OEM vehicle personalization operations take place in five ports of entry on México's Pacific and Atlantic coasts: Veracruz, Tampico, Mazatlán, Manzanillo, and Lázaro Cárdenas. Special Edition operations also take place in four OEM plants across the North and South America. 

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SUPPORT

Air Design infuses a strong spirit of partnership throughout every program --  from the initial award of business to the retirement of tooling at end of lifecycle.  

Striving at every turn to be responsive and easy to do business with, we enthusiastically contribute port installation fixtures, hands-on training sessions, installation videos, and a full team of real people poised and ready to tackle any challenges that may arise.

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PRODUCT LAUNCHING AND MARKETING FOR SUCCESS


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“ Our OE Clients can always count on Air Design’s super capable multicultural team of Graphic Designers and Multimedia producers that ensures success for  every new project in the marketplace!
Air Design supports any project launching with all the necessary POP Material, Social Media contents , and  Installation Vídeos for Training etc. , all produced in-house. “

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