Automotive Prototyping Service

INNORAPID LIMITED
T: +86 (0) 731 8983 2400 E: info@rpworld.com
http://www.rpworld.com
Facilities in Zhongshan: F1-3, Bldg. A1, Henghuifeng Industrial Zone,
DaChong Town, Zhongshan, Guangdong Prov., 528476, P.R. China
RPWORLD
in Automotive Industry
DRIVE TO
THE FUTURE

All the information and documents we received during the cooperation will be treated with
complete confidentiality. We will sign an NDA at your request to ensure
the confidentiality of the information.
Confidentiality
About Us
RPWORLD Service for Automotive Industry
A Tour to RPWORLD
Contact Us

RPWORLD Offers Customized Manufacturing Service to Global R&D Based Clients.
● Digital manufacturing sources for rapid prototyping, low-volume and on-demand production.
● Over 20 years, RPWORLD has developed steadily, and its annual revenue has continued to grow by 30%
over the past 3 years.
● Dedicated to product development in automotive, scientific research, medical device, etc.
Overview
About Us
20+ Years
Manufacturing Experience
20,000+ Projects
Delivered
40+ Countries served
US,CA,DE,IT,CH,FR,…
30%+ Sales raised
in the past three years
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RPWORLD® is a registered trademark owned by INNORAPID LIMITED.

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Our Location and Representative
Italy
USA
Canada
Belgium
We have established global agent business with
representatives located in Europe and North America.
RPWORLD
Sales & Engineering
RPWORLD
Factory
RPWORLD
Headquarters

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Process and After Treatment
| Main Process
3D Printing RIM
Sheet Metal
CNC
Injection Molding
Urethane Casting
| Main After Treatment
Painting Polishing Plating Silk Printing
Water Transfer Printing Coating Laser Etching Brushing
Pad Printing Sandblasting Anodizing Ultrasonic-clean

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Vehicle System
Our Automotive Clients RPWORLD Service for
Automotive Industry
| Body and Exteriors/Interiors System | Power Train System
| Chassis | Electronics System

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During the design validation phase, product engineers can use an automotive prototype to gain clarity regarding their
designs. Prototypes made using cost-effective techniques, are used to create a simple physical object to visualize the
concept and share information with the entire project team.
Automotive Project Milestone
Design Validation Customer Testing Safety Testing Manufacturing Validation
| |
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Vehicle
Feasibility
Approved Sludge
Model
Mule
Car
Data-frozen EP
Vehicle
PVS
Vehicle
0
Series
SOP
Vehicle
Market
Launch
WHAT RPWORLD CAN DO FOR YOU
● What is Design Validation Prototype?
CNC
Sheet Metal
Injection Molding
● What kind of production processes
we use in this stage?
DFMA
CAE Analysis
Material Selection
Full-scale Check
Assembly Test
● What are our advantages?
Design Validation Prototypes
Manufacturing Validation Build Prototypes
Customer & Safety Testing Prototypes

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Project Challenges
● 100 pieces are needed within short lead time.
● Injection molding and sheet metal process applied at
prototype stage.
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The inspection instruments included 2D Automatic image measuring instrument, CMM, pin gauge, etc. We
produced the jig based on drawings provided by customer, and completed the product inspection with
instrument under pre-tightened state. This facilitated us to design the jig according to customer needs in the
following similar projects.
How we provide tailored inspection solutions in the prototype stage?
EPB Actuator Mechanism
Housings
Client Tier 1 (R&D)
Parts
Leadtime 5-7 Weeks
EPB Motor Housing
QTY 300 Sets per Year
Process Injection Molding, Sheet Metal
ROWORLD Solutions
● Provided the specific DFM analysis.
● Full-dimensional inspection.
● Material selection for welding performance.
● CAE analysis, decided to add a gate to interface position.
● We improved the warpage from the initial 1.9mm to 0.5mm.

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● Strict control for injection molding parameters
Referring to the parameters recommended in material datasheet,
we made small-scale adjustments to meet above quality demand.
In addition, injection molding parameters of each product are
recorded to be referred in future repeated production.
● Customized laser transparency testing instrument
We learned that this injection molding material is also transparent
to ordinary light source, and the laser transparency can be detected
indirectly through the transparency of ordinary light source. We
tailored a special gauge and standardized the quality inspection
procedures. Finally, the top and bottom shells inspected under the
tailored inspection method and testing instrument all meet the
customer’s requirements.
● Modify the design to reinforce the structure;
● Optimize the mold gate to improve the fill pressure and
fiber orientation at deformation position;
● Make pre-deformation to increase or decrease the
material at the deformed position;
● Adjust the cooling lines to improve the cooling effect;
● Adjust the machine to try other combinations of injection
parameters;
● Correct the deformation of jig after injection molding.
With overall evaluation and the simulated analysis, we
decided to try Plan B—Adding a gate to interface position
and sent customer the proposal, which turned out to be
satisfying. After several days work, we improved the
warpage from the initial 1.9mm to 0.5mm, saving more time
and cost in production tooling.
How we achieve ultrasonic welding in the prototype stage? How we provide molding simulation solutions?
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Original: 1.9mm
Improved: ≤0.5mm
｜ Laser Transmittance Solution

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Auto Body Parts
Clients Key Concerns
● This part is used to do mechanical performance testing with the entire assembly.
● Prototype material performace should be close to that of mass production.
RPWORLD Solutions
● Use CNC technology to realize tensile strength and other
related designs.
● After confirming key mechanical performance data with
clients, we recommend the most suitable material to match its
mass production piece. COA was provided, and tensile test
was conducted to verify the strength.
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This is a project from a Tier one supplier. It’s an internal structural part of the automobile
shock absorber, made of aluminum alloy processed from CNC machining. However,
die-casting will be its mass production technology.
Client Tier 1 (R&D)
Parts
Leadtime 4 Weeks
Engineering Parts for Assembly Test
(Power Battery Pack)
QTY 30pcs/Batch
Process CNC

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As the customer would like to find the
material close to die cast parts, our
engineering team provide three kinds of
material with COA certificates.
What’s more, we took some samples from
the same aluminum plate of the processed
parts, sent them to an authorised laborato-
ry for corresponding mechanical perfor-
mance tests, and a testing report is issued
for clients to check if it is the one that
meets their mechanical requirements.
How we provide material selection suggestions for our customers?
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Ultimate Tensile Strength 290 MPa
Tensile Yield Strength 145 MPa
Elongation at Break 22 %
5083-O
6063-T6
5052-H32

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● What is Customer Testing Prototype?
Gaining valuable feedback from people
who will be using a vehicle helps
engineers sell their concept to stakehold-
ers, spot possible issues, and decide on
the right materials for the final automotive
product.
● What kind of production processes
we use in this stage?
CNC
3D Printing
Vacuum Casting/RIM
Preassembly
Flexible Decoration
CAS B Creating from CAS A
|

Main Dashboard Assembly
Production technologies and surface treatment available in RPWORLD for interior parts.
● Vacuum casting, RIM (Reaction Injection Molding), CNC , 3D printing , metal sheeting,
etc. combined process to meet with production requirements.
● High capability in surface treatment, including High gloss plating, Matt plating,
Silkscreening, Anodizing, Transfer printing, High gloss painting, Matt painting, Piano
painting, Laser printing, Leather coating etc.
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Main
Dashboard
Assembly
|

Client OEM (R&D)
Parts
Leadtime 3 Weeks
Head Lights
QTY 5 Sets (25 parts of each set)
Process CNC, Surface Decoration
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|

|
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An automotive prototype is vital for safety testing, which can be
performed throughout the pre-production and validation phases
to evaluate possible failures of the automotive product during
actual use.
This testing is called Failure Mode Effect Analysis (FMEA).
During it, automotive prototypes are placed through different
scenarios and subjected to extreme conditions to identify any
problems that could hamper the use of the product or cause
serious safety concerns to consumers.
● What is Safety Testing Prototype?
Urethane Casting, RIM
Sheet Metal, Injection Molding
● What kind of production processes we use
in this stage?
Material & Process Selection
Delivery on Time
In-process Inspection of Critical Dimensions
● What are our advantages? Safety Testing

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Center Console
Instrument Panel
Door Panel
Client OEM (R&D)
Parts
Leadtime 8 Weeks
Center Console, Instrument Panel
and Door Panels
QTY 60 Sets for 300+ Parts
Process Vacuum Casting, RIM, Surface Decoration
|

Due to limited time, we simultaneously design
and manufacture the multifunctional fixture, it
not only completes the assembly welding but
also serves as a checking tool for testing
whether the product is qualified.
The drawing on the left was sent to client to
confirm, and we start the production after getting
their approval. In the subsequent production of
the welding jig, every step is finished with CMM
testing to ensure the accuracy of the tooling.
And after 6 months, the client told us that our
solution of rapid sheet-metal process resulted in
better accuracy than the samples obtained from
mass production factories.
These results are got from CMM testing,
they are all marked green, which means that
all the tolerance are within control values.
The client is a well-known automotive company. Their mass
production supplier could not provide 47 sets of Cross Car Beam
(CCB) as planned, while assembly of the prototype vehicle had to
be started within one month. As a long-term strategic partner, we
were asked to help the client to solve the problem.
Challenges
● Verify the installation points between beam and body-in-white
● Ensure the assembly of beam, instrument panel and other parts
● Tight schedule
ROWORLD Solutions
● Process optimization
● Design and customize welding jig
● Measurement by CMM
Cross Car Beam
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Custom Mold & Fixture
CMM Inspection Results
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Water Tank
● What is Manufacturing Validation Prototype?
The manufacturing validation build uses the intended equipment and machinery to create the final automotive
prototype so that finishing touches can be made before production tooling is engineered.
As an outstanding car parts supplier in Germany, the client has cooperated with several world-famous automobile
manufacturers for years.
They were looking for 30-50 sets of newly-designed water tank of advanced automobile to test the performance.
Material COA was provided as mass production material was required. To complete the performance test soon and
start mass production, the client expected to receive the prototypes in the shortest time.
There is a complex geometry structure with big size, injection molding was the best solution to process it. And the
project was delivered on time.
● What kind of production processes we use in this stage?
Sheet Metal
Injection Molding
Die Casting
Material Tracibility
One-stop Solution
Delivery on Time
In-process Inspection of Critical Dimensions
Great Quality and Well-priced
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Design Validation
Prototypes
Customer Testing
Prototypes
Safety Testing
Prototypes
Manufacturing Validation
Build Prototypes

Our Factory
Why
RPWORLD
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Inspection Facilities
▲ 3D Scanning for Large Parts ▲ Color and Surface Check
▲ Dimension Measurement
▲ Raw Material Inspection

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Material Reports
RoHS REACH
Facility Certificates
ISO 9001 DUNS
Calibration
IATF 16949 and ISO 14001
On the way...
ISO 14001
COA

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Inspection Report Schedule Management
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Measurement and Material Inspection Report Quality Inspection Report

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Package and Shipment What Can You Expect from RPWORLD
Standard
Packing
Shipment
Selection
Customized
Packing
R
Project Management
Design Optimization
Lessons Learned
Quality Control Checklist
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Rapid
Lead Time：30%↑
On-time Delivery: 98%↑
Problem Solving: 50%↑
√
√
√
Customer
Service
Customer Orientation
After Sale Process
√
√
√
√
Professional
Rich Experience in
Automotive
Developed-industry
Base in Guangdong
Technical
Support

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Contact
Us
How to Work
with Us
Sending Inquiry
● BD Contact
● NDA Signed
● Request for Quotation
Pre-Production
● PO Confirmation
● Incoming Material
Inspection
Delivery
● Customized Packaging
● Follow-up on Delivery
● Client Feedback
DFM Analysis
● DFMA Report
● Commercial Plan
Manufacturing
● Various Processing
Techniques
● FAI
● IPQC
● Surface Treatment
● OQC

Customer Testimonials
Very Responsive
“Innorapid is very responsive to evolving
needs. Many new projects come with
tight deadlines, but they are always able
to work within our timelines to deliver
quality parts on schedule.
They really Follow their motto “Under
promise, over deliver” and are definitely
a good partner!”
From Project Manager of a Tier I Supplier
I would like to take a few minutes to
thank you and RP World’s team for
your support in resolving prototype
issues for the latest aluminum parts.
This is in those situations that we can
see the value of professionals and a
trusted partners like RPWORLD.
From the President of a Large Design
Firm
Trusted Partners
Please be assured I often talk about
the quality of products we got from
Innorapid. We got many CNC
machined plastic components from
your company and were very pleased
of the result.
From Manager of New Product
Development
Quality Highly Professional
The mockups were executed with a
high-level of care, and the interaction
with your team was highly profession-
al, with your manufacturing and design
team very proactive in proposing
solutions and clarifying details.
From the Industrial Design Manager of
a Well-known Automotive Company
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Automotive Prototyping Service

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