Automotive Polymer Floor Mat and Forming Tooling

This project involved the development of a polymer automotive floor mat and its forming tooling based on a 3D scan of the vehicle interior floor. The scan data was prepared and used to construct working surfaces that defined the product geometry and its fit within the vehicle interior. The project included: • Preparation and analysis of the 3D scan • Construction of working CAD surfaces • Development of the floor mat geometry • Design of the surface relief • Development of retention and fixing zones • Creation of forming surfaces • Design of sheet-metal tooling components • Preparation of tooling flat patterns • Verification of the relationship between the product, scan, and tooling The final deliverables included 3D models of the floor mats and forming tooling together with flat patterns for sheet components. The project was completed in 10 days.