Step Illumination / Door Sill Plates

Autocop
Written By RG .

🔧 Tools & Technologies:

CATIA V5, Plastic Injection Moulding, Light Guide Technology, LEDs, Ultrasonic Welding, GD&T, Mould Flow Analysis

📄 Overview

This project involved the design and development of illuminated scuff plates (step illumination) for passenger vehicles. The product is mounted on the rocker panel and lights up the name of the respective vehicle when the door opens, enhancing both aesthetics and visibility.

🎯 Objectives

  • Design a functional and visually appealing step illumination accessory

  • Ensure manufacturability using plastic moulding techniques

  • Meet OEM standards for both Honda and Toyota

🧠 What I Did (Role: Project In Charge)

  • Concept design and 3D modelling using CATIA V5

  • Developed prototype parts and conducted mould flow analysis to reduce sink marks

  • Created technical drawings using GD&T and prepared kit drawings

  • Designed checking fixtures for product testing

  • Participated in product validation and testing

  • Managed Bill of Materials (BOM) and assigned part numbers to components

  • Collaborated closely with OEMs like Honda and Toyota Kirloskar Motor (Bidadi, Bengaluru)

RG .
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