Class-A Surface Development + Maturation Methods

| CLASS-A SURFACE DEVELOPMENT + MATURATION METHODS0
Nick Boyd
Product Design Engineer
05.18.2016
INTEGRATED SURFACE /SOLID MODELING DEMONSTRATION

This document provides an overview of the creation and maturation of an Audi R8’s Class-A surfacing. The
intent of the exercise was to represent the finalized styling in a manner consistent with the vehicle’s
character curves and final implementation performed in a manner congruent for further development.
A. INITIAL SETUP
1. GEOMETRIC DATA ORGANIZATION
2. MASTER MODEL
3. CONTROL + CHARACTER CURVES
4. PARTING LINES
B. FUNCTIONAL ASSEMBLIES
5. FRONT BODY
6. MIDDLE BODY
7. DOOR + SIDE ACCENT
8. REAR BODY
9. REAR BUMPER
10. HEADLIGHT
11. GRILLE
12. WHEEL + TIRE
C. FINAL PRODUCT
11. PERSPECTIVE VIEW
12. SIDE VIEW
13. TOP VIEW
14. SUMMARY
OVERVIEW|PRESENTATION ORGANIZATION

A high degree of thought was given towards a consistent organization of 2-D and 3-D data.
Separation of Inputs, Construction and Outputs allows for ease in the surface development
and final refinement form.
Geometrical Set Flow
INITIAL SETUP|GEOMETRIC DATA ORGANIZATION

INITIAL SETUP|MASTER MODEL
The major focus of the project was to replicate the design of the Audi R8 with attention
to a logical and properly constrained workflow. First steps included the precise alignment
of isometric projections in order to develop 3-D curves.

Surface construction began with Control and Character Curves. 3-D curves were
generated through the Combine function and adjusted for appropriate surface
termination and blending with adjacent geometry.
INITIAL SETUP|CONTROL + CHARACTER CURVES

To create surfacing in a development-ready manner, surfaces were created that reproduced
body panel break lines. This would allow for cohesion of functional assembly region of the
car through the splitting of a “master” surface.
INITIAL SETUP|PARTING LINES

Significant focus was brought on reproducing surface relation and terminations as
accurately as possible to reality. Addition of splitting lines and filleting represent a
final product with discrete component characteristics.
FRONT BODY ASSEMBLY| OVERVIEW

Beginning stages of the surfacing process began with creation of Fills, Multi-Sections
and Sweeps that are subsequently trimmed together. Continuity and Tension
parameters were adjusted to capture character of reference form.
FRONT BODY ASSEMBLY|SURFACE DEVELOPMENT
 SIDE PROFILE DEVELOPMENT:
 FENDER TRANSITION AND BLENDING:
+

Development continues with the repetition of additional sketches, surfaces and
trimmed surfaces being incorporated into the model. Discrete components of the
overall assembly are framed-out and begin to take shape.
 FENDER SURFACE REFINEMENT:
 HEADLIGHT DEFINITION:

The assembly progressed towards its final form, including the definition of discrete
components. Additions such as filets developed the form while maintaining the
original path of the character curves.
 APERTURE PROFILES:
 BODY PANEL SPLIT + OFFSET:
+

Final touches to this geometry region included the addition of surfaces giving the
outer skin the “dimensionality” of a pre-production product ready for refinement.
This logic is repeated in other major assemblies for consistency.
 SPLIT + FILET:
 TRANSLATE + TRIM + FILET REFINEMENT:
+
+ +

This surfacing group was the basis for the majority of side and rear components. As with
the master surface, it was important to develop an initial and congruent form from which
further refinement could be performed to obtain discrete components.
MIDDLE BODY ASSEMBLY|OVERVIEW

Initial surfacing began with the roof area of the car and transitions to both the side and the
rear design elements. Base surfaces where utilized in conjunction with parting surfaces in
order to ensure continuity of form.
MIDDLE BODY ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:

MIDDLE BODY ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Refinement of this assembly’s elements continues to be performed. Special attention was
focused on the transition zone to the rear wheel well where complex geometry exists.
Several rounds of surface creation, trimming and surface re-creation were utilized.

DOORS + SIDE ACCENT ASSEMBLY|OVERVIEW
These elements were derived from the aforementioned Middle Body Assembly, this
allowed for ensuring that the profile and sectioning of the model were consisted with the
reference model. Additions such as the window and mirror provided added dimension.

DOOR + SIDE ACCENT ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Geometry in this section utilized the offsetting of source surfaces in order to create both
apertures and further general styling cues. Integration of the mirror and handle elements
were complex entities and took many refinements to maintain accuracy.

DOOR + SIDE ACCENT ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Further utilization of apertures and integration of character curves drove the
developments of the door element further into more complex forms. Implement this
standard geometry architecture allowed for the refinement of the side accent.

REAR BODY ASSEMBLY|OVERVIEW
The Middle Body again presented itself in this geometry area with the integration of body
panels, accent features and those with optical properties. This was another very complex
area that required many iterations of surfacing to deliver an accurate result.

REAR BODY ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Integration of parting surfaces were the focal point of the initial surfacing refinement. Of
special attention in this process was the sub-division of existing surfaces, extraction of
reference edges and tension/continuity tuning of transitional zones.

REAR BODY ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Discrete components of this assembly became more refine and defined in this stage of the
development process. The original character curves were again utilized to maintain a
continuity of form throughout the final product.

REAR BUMPER ASSEMBLY|OVERVIEW
This section is a further refinement of the Middle Body and contained a multitude of
surfacing interaction as this area is complex in its geometry. The addition of solid part
modeling was also incorporated in the development of the exhaust components.

REAR BUMPER ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Development in this area was highly dependent on its surrounding surfacing to develop
the general form. In addition, numerous unique surfaces where incorporated into the
geometry giving complex styling characteristics.

 SPLIT + FILET:
Depiction of further refinements to the assembly form were once again driven by the
importance of replicating the reference form as closely as possible. Elements such as the
rear splitter and exhaust packaging were integrated accordingly.

 SPLIT + FILET:
Final stages of this area’s development included the definition of the rear bumper sections
separated by material application. A parting surface the was utilized in previous assemblies
was applied here in order to further maintain form continuity.

HEADLIGHT ASSEMBLY|OVERVIEW
These elements were developed to display design intent of this assembly area. As the
optical properties of a headlight are extremely complex, the approach with this area was
to refine the geometry without over-complication of the final form.

HEADLIGHT ASSEMBLY|SURFACE DEVELOPMENT
 SPLIT + FILET:
Refined surfaces from the front body assembly were combined with aperture definitions
to resolve the headlight and surrounding geometry. Solid body modeling was utilized to
develop the styling below the headlight lens representation.

GRILLE ASSEMBLY|OVERVIEW
Development of this section was unique in the fact that the majority of its construction
was done through Solid Part design. Utilization of feature patterning and mirroring
techniques that allowed for expedited completion.

GRILLE ASSEMBLY|SURFACE + SOLID DEVELOPMENT
 SPLIT + FILET:
Surface design was the initial driving method for form development – specifically
previously used Parting Surfaces. After this boundary definition, solid components were
integrated to complete the refinement process.

WHEEL + TIRE ASSEMBLY|OVERVIEW
Construction of this element presented another blending of Surface and Solids modeling.
Patterning of cutting forms was critical in the development of both tire and wheel forms as
can be observed in their final characteristics.

WHEEL + TIRE ASSEMBLY|SURFACE + SOLID DEVELOPMENT
 SPLIT + FILET:
Development of the wheel began simplistically and grew in complexity rapidly through the
implementation of the Pattern feature. This approach allowed for a detailed model to be
constructed in an efficient and easily updatable format.

WHEEL + TIRE ASSEMBLY|SURFACE + SOLID DEVELOPMENT
 SPLIT + FILET:
The Tire maturation process also used the Pattern feature in order to drive the tread
creation process. As actual tread patters are highly complex and functionally designed, the
intent of this model was to provide a close approximation of the reference form.

FINAL PRODUCT|PERSPECTIVE VIEW
Surface construction began with “Control” Character Curves. 3-D curves were generated
through the Combine function and adjusted for appropriate surface termination and
blending with adjacent geometry.

FINAL PRODUCT|SIDE VIEW

FINAL PRODUCT|TOP VIEW

FINAL PRODUCT|SUMMARY

Class-A Surface Development + Maturation Methods

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