Made in Germany at one location

Development partner for product development

Design from concept to market-ready product

Product development, construction

We develop concepts primarily for plastic products and assemblies and support their development processes for our customers from many industries such as automotive, mechanical engineering, electrical engineering, consumer, industrial and others. For you, this means: expert knowledge in product development with a focus on plastics technology and module development since 1991.

We have acquired particular knowledge in developing complex interior components such as armrests, headrests, cup holders and premium seat components for the automotive sector.

We also have extensive expertise in the design and construction of clever housing solutions for various industries, including mechanical engineering, electrical engineering, consumer and industrial products.

The smooth process is made possible by the support of a permanent contact person from enquiry to project handover.

At a glance

Expert knowledge in design and product development since 1991
Development of interior components such as armrests, headrests, cup holders and the like for all OEMs
Development of clever housing solutions for various industries such as automotive, mechanical engineering, electrical engineering, consumer and industry.
Profound engineering expertise with a focus on plastics technology from individual parts to complex assemblies
Use of Dassault Systems Catia and Siemens NX CAD systems

5 steps to a production-ready product: Minimize development and investment risks

With our 5-phase development, acad engineering systematically secures every step of development. After completing and analyzing each individual phase, you decide when and how to proceed with the next phase. For you, this means minimizing your investment and development risk. The phases are clearly defined and consist of the following stages:

Stage 01

Concept phase

Together with you, we develop a specification and then initial concept ideas. Together with you, we will select the most promising concept. Even during the concept phase, we take into account tolerance chains of as few components as possible and RPS alignment concepts between the components when assembling them.

Stage 02

Detailed phase

This is followed by a rough 3D processing of all components, taking into account the environment. After the first rough 3D development, we carry out FEM preliminary analyses to check the characteristics of strength, stiffness, misuse and durability.

Stage 03

Functional sample phase

The 3D data from the processing phase is already suitable for building initial principle and functional patterns. These can consist of various rapid prototyping processes, such as SLS, STL PUR casting resin or CNC-machined parts. These are already limited in terms of feel, function, assembly and handling

Stage 04

Elaboration phase

After the first detailed and functional sample phase, we process the 3D design, with the aim of selecting the optimal manufacturing process for the planned volumes and developing individual components that can be manufactured as cheaply as possible. We carried out inquiries for parts prices from various manufacturing processes such as steel parts - extrusion, turning, milling, metal powder sintering MIM technology, etc.This phase is decisive for a successful, market-ready product We support you during the development of your Development FMEA, and develop an error and risk analysis with Wihnen.

Stage 05

Drafting phase

First individual part drawings or ZB drawings are required to request the indicative parts prices

Stage 01

Concept phase

Together with you, we develop a specification and then initial concept ideas. Together with you, we will select the most promising concept. Even during the concept phase, we take into account tolerance chains of as few components as possible and RPS alignment concepts between the components when assembling them.

Stage 02

Concept phase

Together with you, we develop a specification and then initial concept ideas. Together with you, we will select the most promising concept. Even during the concept phase, we take into account tolerance chains of as few components as possible and RPS alignment concepts between the components when assembling them.

Stage 03

Concept phase

Together with you, we develop a specification and then initial concept ideas. Together with you, we will select the most promising concept. Even during the concept phase, we take into account tolerance chains of as few components as possible and RPS alignment concepts between the components when assembling them.

Stage 04

Concept phase

Together with you, we develop a specification and then initial concept ideas. Together with you, we will select the most promising concept. Even during the concept phase, we take into account tolerance chains of as few components as possible and RPS alignment concepts between the components when assembling them.

Stage 05

Concept phase

Together with you, we develop a specification and then initial concept ideas. Together with you, we will select the most promising concept. Even during the concept phase, we take into account tolerance chains of as few components as possible and RPS alignment concepts between the components when assembling them.

Services — Testing & Simulation

Numerous simulation and testing tools accompany the development process and ensure a good 3D design. At acad, simultaneous engineering is consistently implemented. This avoids superfluous development loops.

By applying the finite element method to entire assemblies at a very early stage, even in the rough concept phase, they can be assessed for their suitability in terms of stiffness and strength. With a very simplified 3D design of a structural component made of plastic, you can already gain insights into the suitability of a plastic or the structure of a component. With the option of static strength tests, these results can be directly verified and confidence in the simulation results can be strengthened.

Thanks to the rehological analysis of plastic injection-molded parts, the optimal sprue position can be determined during development and thus statements can be made about the filling behavior, shrinkage and distortion behavior. The dimensional qualification of components or entire assemblies is ensured by an ATOS Compact Scan measurement system from GOM.

We offer you a selection of different testing and simulation methods.

01

Finite element assembly analysis

FEM — finite element method with assembly structures.
Simulates assemblies under static load conditions. Analysis of complete assemblies — here load on a cupholder floor. Calculation within a platform with fast, direct response to geometric design changes.

Very quick qualitative optimization of concept proposals is possible.

02

Rheological analysis of plastic injection-molded components

Rheological design of plastic injection-molded parts with CADMOULD simulation of plastic injection-molded parts during development. Possibility of coordinating the geometry of injection-molded components in in-house tool design.

03

Construction space analyses

Motion simulation and construction space analyses with DMU Kinematics Calle vsFunctional and space validation of kinematic house groups

04

Static strength test

Force-distance measurement device enables initial prototypes to be evaluated (validated) and optimized during the development process

Force measurement tests including test reports
Design and manufacture of recording geometry in house

05

Part measurement with GOM ATOS Compact Scan

Component testing with optical measurement system
GOMComponent measurement, test report Tolerance analysisReverse engineering/area return

06

Fixture construction

Design and manufacture of holding and mounting devices. Test recordings for armrests, housings, etc. to validate forces and adjust functions. Structures for partial and final assembly

07

Functional model construction

Procurement of functional models made of plastic or metal from various processes such as SLS, SLA, PU casting resin, metal sintering. Development of functional and principle patterns, including evaluation and documentation. Assembly of complete assemblies for pre-series

Reference projects

Product development

Daimler BR223 S-Class center armrest and rear opening project for F.S. Fehrer Kitzingen GmbH

Product development

Smart infinitely height-adjustable armrest development project for F.S. Fehrer Kitzingen GmbH

Product development

Development project of the Apollon-Q level sensor housing for Sentinum. High-strength housing for outdoor use with protection class IP66. Sealing with injection-molded 2K soft component. In-house toolmaking and production of pre-series production at acad group.

Product development

DTS 20 CA diamond wall saw handle/housing development project for Hilti. Metal replacement/ weight loss. Ergonomic optimization. Processing of PPLGF30 in thermal foam casting and PP coated with grained surface (handle). Processing of PA6GF35 (cover) toolmaking and small series production at acad group in-house.