From this article you will know:

1. Systems Engineer – who?
2. What exactly Systems Engineer do in Automotive?
3. How to become a Systems engineer.

Projects in automotive

Projects in Automotive are very multi-dimensional and complex, the complexity of the projects is a result of the complexity of modern cars itself, which differs from cars from 10-20 years ago. The progress was mainly about increasing safety, but also adding technology and upgrading multimedia. Does that mean that older cars weren’t safe? They were, but this was only passive safety. Passive safety means equipment that works during or after the crash. Modern cars have active safety systems, that should prevent the crash.

You could ask yourself – is that technology complicated? In a word: VERY! In a modern car, you could find almost 3 kilometers of different wires.

The technology used in modern cars is intended, among other things, to protect the driver, passengers and even pedestrians (actively and passively), ensure the highest comfort of travel and provide entertainment, i.e. simply make traveling pleasant and not boring, even if nothing is interesting outside the window.

Systems Engineer – who?

First of all, I should start by explaining the difference in responsibilities for this role between the IT and automotive industries. If you are not aware of this difference, you will be in for quite a surprise during the job interview.

In IT the duties of a Systems Engineer are:

• manage and monitor all installed infrastructure systems
• installing, testing, configuring, and maintaining operating systems, application software and system management tools
• analyzing and designing process automation, e.g. using C # and Microsoft .NET Framework and various system APIs

The tasks above are significantly different from the duties of a Systems Engineer in Automotive. If you would ask us, we would say they are closer to Software Engineer.

So, is there a role in IT for a System Engineer? Yes! The closest role would be Business Analyst.

Systems Engineer in automotive

It’s not that easy to find a clear, simple definition of Systems Engineer responsibilities.
A systems engineer is a bit of an “all-rounder” – for everything and for everyone. Often, due to the project’s characteristics, two Systems Engineers with five years of experience may have completely different knowledge and experience.

In Automotive Systems Engineer is mainly responsible for:

• requirements database management
• analysis of customer requirements
• agreeing/defining requirements with the client
• writing system requirements
• supporting the creation of system architecture or just the creation  of system architecture
• ensuring compliance with the ASPICE process (in the context of the system part)
• support for other engineering competencies for which system requirements are input documents

One of the key tasks of a System Engineer is to create and maintain a requirements database, i.e. a set of documents with the client’s vision regarding how the product should look and work, but also which norms and standards the product should meet. Documentation may take different forms depending on the client.

Requirements from the customer included in the documentation are reviewed and assigned to a given competence (e.g. mechanical, validation, software, tests, electrical) and then further reviewed by the previously assigned competencies.

Requirements review is a cyclical process, it is a rare or rather impossible scenario when all issues included in the customer’s requirements are clear to engineers. Many questions / open points arise at the stage of requirements review. The task of the Systems Engineer is to fill in the gaps and clarify unclear issues. Then the cycle repeats itself until each requirement is understood, and we know exactly how to implement it and how to test it.

It’s not always as simple as it may seem. It is the responsibility of the system engineer to ensure the periodicity of the requirements review process.

A useful thing for a Systems Engineer is well-developed soft skills, he needs to be able to get along easily with people. It’s useful not only during the requirements review process mentioned above but also during negotiations with the customer. The Systems Engineer is most often the interface connecting the client’s vision with other engineers in the project.

It often happens that during the analysis of customer requirements, it is necessary to get support from other competencies that specialize in a given field (e.g. Software, Mechanical, Electrical, Validation). Then, the review and analysis of the customer’s requirements takes place in a group of engineers, but the Systems Engineer is responsible for the negotiation and clarification of requirements with the customer.

For example:

• We are able to perform the operation on a given processor, but it can be done in 200 ms and not in 100 ms as it was initially written in the design documentation.
• Selected materials will withstand 150,000 repetition cycles during validation tests and not the 200,000 cycles specified in the requirements.

Sometimes it happens that the customer expects things that are impossible to implement within the budget or equipment set for a given project, but he’s completely unaware of it. In such a situation, well-developed soft skills should come in handy again, because the Systems Engineer, as the first line of contact, should clarify this issue with the client.

Quality

Another aspect of the Systems Engineer’s responsibilities is ensuring the quality of a product. Quality in the form of creating project documentation in accordance with the norms and standards applicable in the automotive industry (e.g. ASPICE). Here, support from quality engineers is extremely important, close cooperation with “quality” is crucial to embrace the appropriate strategy and creating documentation to meet the required processes.

Are these all the duties of a Systems Engineer in the automotive industry? Of course not, and often the scale of responsibilities is much greater than what is described above, the rest can be included in the term “cooperation with other engineering competencies” and depends mainly on the characteristics of the project being implemented or even depends on the customer for whom the project is being implemented.

Systems Engineer is often responsible for topics such as:

• Cooperation with the production factory
• Performing the so-called production releases
• Memory map definition for each production release
• Supporting system tests
• Work on improving the product
• Participation in quotations for new projects
• Carrying out measurement tests
• Conducting technical workshops with the client and sub-suppliers
• Participation in product design
• Different researches on the market for product optimization or product legalization

Of course, these are not all the activities and responsibilities performed by the Systems Engineer role. For example, a project based on a camera to monitor the interior of a vehicle will require a lot of recordings for neural network training and testing.  In another project, e.g. Body Computer, the system specialist will only deal with requirements, documentation and process.

It is worth mentioning that in recent years, a Systems Engineer has been required to have knowledge of Functional Safety and Cybersecurity, at least at a basic level, despite the fact that domain specialists are employed to cover these issues in the project. It should also be noted that during the AGILE transformation of the automotive industry, it is increasingly often the system specialist who serves as the Product Owner/Function Owner.

Just how wide a spectrum of responsibilities can be covered by a Systems Engineer? Given the current scale of the diversity of projects carried out to build electronics for cars, it is difficult to say, because the number of electronic components in cars is constantly growing and each of them may have a completely different character of the project and, consequently, a completely different scope of responsibilities for the Systems Engineer. Just look at the graphic below to understand the scale of technological advancement of the modern car.

How to become Systems Engineer?

There are many possibilities, some people with experience in the industry decide to change their career and choose the path of a Systems Engineer – most often they are testers or software engineers, but they can also be quality engineers etc.

Several years of experience and a good understanding of the automotive industry make it easier to fit into the role of a Systems Engineer. A good introduction to the role of a system specialist is the position of a Requirements engineer. The main task of a requirements engineer is to write requirements and conduct reviews of existing requirements. Requirements Engineer is a good introduction to the role of Systems Engineer because the tasks performed in this role partially cover the scope of responsibilities of a systems engineer.

Summary

There are many different roles in the Automotive industry, System engineering is not the easiest one, it requires knowledge, experience and a good understanding of the business and the principles of the automotive industry. The role of a Systems Engineer is a nice balance between working with documentation and working with people. If you are open to different, often unconventional solutions, can think analytically and like working with people, this is definitely something for you.

Initiatives undertaken and implemented by Polish companies are gaining considerable publicity in this context. An excellent example of this is the SM42-6Dn hydrogen locomotive designed by PESA Bydgoszcz. The granting of its homologation by the Office of Railway Transport (Urząd Transportu Kolejowego) was met with considerable media interest, not only in the industry. The hydrogen railway fires the imagination and gives hope for a significant reduction in the carbon footprint of rail transport in the coming decades. We encourage you to read the article, in which we briefly describe:

• the history of the hydrogen railway
• the location of the Polish hydrogen railway industry – led by the Bydgoszcz-based company PESA,
• challenges and prospects for the development and uptake of hydrogen trains.

History of hydrogen rail – how has the concept developed over the years?

For more than 20 years, hydrogen locomotives and other technological solutions based on the use of this fuel have been one of the key issues in the discussion on the future of rail transport. However, the very concept of using a hydrogen fuel cell to power vehicles is much older. Its practical use in engineering was first encountered as early as the mid-1960s when it was installed on board the space shuttle that took part in the Apollo mission. Outside the space sector, however, the solution did not prove to be a breakthrough. Barriers to its development and dissemination included the low level of environmental awareness at the time and the relatively high cost of the technology.

Attempts to implement hydrogen cells in buses began as early as the 1990s, but it took until the new millennium for this technology to begin to be developed more intensively in public and private transport. Suffice it to mention that the conventional date for the first use of the term ‘hydrogen railway’ is 22 August 2003. The phrase was coined when giving a presentation on the ‘Mooresville Hydrail Initiative’ at the US Department of Transportation’s Volpe Transportation Systems Centre in Cambridge. Interestingly, the first hydrogen-powered mine locomotive was demonstrated in Canada in 2002. – which was a year earlier. As an indication of the scale of the challenges involved in implementing hydrogen technology, it took until 2006 for a hydrogen railcar to be implemented, and another 12 years for the Coradia iLint model – the world’s first hydrogen-powered commercial passenger train – to enter service. On 17 September 2018, the first two vehicles of this type were put into service in Lower Saxony.

The potential of hydrogen rail is recognized by many countries seeking to modernize their rail transport. Investments in hydrogen or hybrid (hydrogen-electric) trains are planned and underway in France, Italy, and England, among others. By using this technology, British railways intend to phase out the use of diesel trains completely by 2040. Countries outside of Europe, such as Canada, the USA, and South Korea, are also interested in the hydrogen passenger train concept. It is worth noting that work is also underway on hydrogen locomotives used, for example, for shunting work at marshaling yards or inside industrial plants.

At what stage are works on the development of hydrogen railways in Poland?

Investment in the development of hydrogen trains and locomotives is also taking place in Poland. It is worth noting that, as a priority, hydrogen-powered railway vehicles are being used as an alternative to diesel trains on non-electrified lines. Our country compares very well with the EU average in terms of the rate of electrification of lines, so it would seem that there would be less interest in hydrogen trains and locomotives. This is a mistaken impression – in Poland, there is a low level of use of the railway network, which is linked, among other things, to the limited service of non-electrified lines. If decisions are taken to increase the level of use of the rail network, hydrogen trains could prove to be a very beneficial solution for decarbonizing Polish railways.

Work on the project, which is Poland‘s first hydrogen locomotive, was started several years ago by the Bydgoszcz-based railway company PESA. The result of this project is the SM42-6Dn shunting locomotive, which is powered by two hydrogen cells. It is equipped with four asynchronous traction motors of 180 kW each and access to hydrogen tanks with a capacity of 175 kg. The hydrogen cells generate energy and, via a traction battery, power all four engines. This enables the locomotive to reach a maximum speed of 90 km/h. Importantly, the capacity of the hydrogen tanks is adapted so that one refueling allows a full 24 hours of shunting operation. It is worth adding that the SM42-6Dn shunting locomotive has a built-in obstacle recognition system and an autonomous driving system. This allows the engine driver to radio control the vehicle one-on-one when setting up trainsets.

The Bydgoszcz-based hydrogen-powered locomotive premiered at the TRAKO 2021 International Railway Fair and was approved for operation by the Railway Transport Office in mid-2023. A Polish hydrogen train will be built in the near future. PESA Bydgoszcz plans to launch the first passenger trainsets using hydrogen cells by 2026.

Why could the hydrogen train revolutionize rail transport?

The drive to decarbonize rail transport is leading more and more countries to allocate large amounts of funding to the development of hydrogen trains. What makes such high hopes for this technology?

Emission-free

One of the main reasons why hydrogen rail is attracting so much interest is its environmental potential. Burning hydrogen involves no greenhouse gas emissions. The only by-products of its use as a fuel are heat and water.

Safety and energy efficiency

A major advantage of hydrogen cells is their energy efficiency. This is largely due to the characteristics of hydrogen, which, relative to mass, has the highest calorific value and heat of combustion among fuels. Equally importantly, hydrogen trains are not inferior to conventional modes of transport in terms of safety.

Possibility of replacing diesel trains

The implementation of hydrogen trains makes it possible to reduce the number of diesel trains running on non-electrified lines. Overall, hydrogen trains can also contribute to the energy efficiency of rail transport, as hydrogen locomotives have good efficiency, being able to travel long distances without frequent refueling.

Noise reduction

An important advantage of hydrogen trains is their low noise emissions, which is particularly important for the comfort of those living close to the railway tracks.

Efficient operation at low temperatures

Hydrogen cells, which are the basis of railway hydrogen technology, are characterized by efficient operation at low temperatures.

Beneficial alternative to electrification of railway lines

Hydrogen rail is a worthwhile alternative to investment in rail electrification. This aspect is particularly relevant for markets such as North America, for example, where electrified lines are very rare.

Versatility

A point worth noting in the context of the use of hydrogen in the railway area is also its wide range of applications. Based on this technology, it is possible to modernize many different types of rail transport, including passenger, freight or industrial rail, among others.

What are the challenges of a hydrogen railway?

The road to achieving the goal of cost-effective and efficient deployment of hydrogen trains is not straightforward. One of the main problems to be tackled is the need to invest in the right infrastructure. Among other things, it is necessary to have an extensive network of hydrogen refueling stations and to train a sufficient number of employees who will have the knowledge needed to properly operate and maintain the entire system.

Another challenge associated with the hydrogen revolution in rail transport is how to obtain the hydrogen itself. Some of the fuel cell trains tested to date have used so-called grey hydrogen, which can be the product of methane reforming, coal gasification or the breakdown of water into individual elements. The use of energy- and emission-intensive processes in this context contradicts the ecological idea of hydrogen railway technology. The long-term goal is to use so-called green hydrogen, which is obtained by electrolysis using energy from renewable sources such as wind farms or photovoltaic panels.

Summary

The potential inherent in hydrogen trains means that many countries around the world are choosing to invest in this technology. The emission-free capability that modern hydrogen-powered rail vehicles will be able to provide could make them the foundation of a future ecological revolution in rail transport. However, there are more than just environmental arguments in favor of funding the development of hydrogen railways. Other important advantages of hydrogen trains include their efficiency, low noise levels, safety and efficient operation at low temperatures, among others. However, the cost-effective deployment of railway vehicles is associated with certain challenges, such as the need to create the appropriate infrastructure, educate the workforce, as well as the efficient acquisition of green hydrogen.

The design of hydrogen-powered rail vehicles is an endeavor that requires the specialists involved to have the necessary know-how and many years of experience in implementing advanced technological projects in the area of rail transport. Knowledge of the specifics of this sector is crucial, as the nature of rail vehicle production differs significantly from the standards according to which, for example, industrial design in the automotive industry is carried out. At Endego, we have specialized in conducting technology projects for companies in the rail industry for many years. We have successfully cooperated with leading national railway companies such as PESA, the developer of the first Polish hydrogen locomotive, and Polski Tabor Szynowy – Wagon, among others.

Are you looking for a proven engineering team with experience in designing key elements that affect the functionality, efficiency and aesthetics of rail vehicles? Contact us and let’s create the future of rail transport together!

Hydrogen-powered vehicles are one of the fastest growing areas in the public transport sector. This is influenced, among other things, by various subsidy programmes to support the implementation of clean public transport. In the remainder of this article, we will analyse, among other things, why there is so much interest in hydrogen buses, what their main advantages are, what their general principle of operation is, and what the current situation is regarding the use of this type of low-emission vehicles in Poland and around the world. 

Hydrogen bus – one of the cornerstones of public transport of the future 

Increasing the energy efficiency of vehicles and the use of renewable energy are currently among the strategic objectives of European transport and energy policy. The motivation for taking action in this direction is primarily the desire to prevent progressive climate change and an increase in air pollution. As road transport is a significant factor negatively affecting urban air quality, public transport has become one of the areas of particular focus in the development of new, greener technologies. 

The process of modernising public transport and transforming it towards low-carbon modes of transport has become multifaceted over the years. An important part of the focus in recent decades has been on electromobility, understood mainly as BEVs (Battery Electric Vehicles), i.e. vehicles powered by electricity stored in rechargeable batteries. During this time – somewhat in the shadows, one might say – there has also been systematic progress in the use of hydrogen technology for propulsion in buses and trams. This has been fostered by various initiatives such as, among others, the international CHIC project, which aimed to support the market introduction of hydrogen fuel cell buses. 

For some time now, we have also been able to observe the rise of public transport based on fuel cells in Poland. On the streets of larger and smaller cities in our country, it is increasingly common to see hydrogen buses running on a regular basis, attracting passengers with modern, ergonomic equipment and practical amenities such as free Wi-Fi or USB sockets for charging phones. The development of the situation in this area is evidenced by one of the indicators for achieving the goals set out in the Polish Hydrogen Strategy until 2030 with an outlook until 2040: 

• 100 to 250 buses by 2025, 
• 800 to 100 buses by 2030. 

It is worth asking at this point why such high hopes are being pinned on hydrogen buses. The most important factor that determines the belief in the breakthrough nature of this type of vehicle is the many advantages of hydrogen as a fuel. What are the most important advantages of using hydrogen fuel cells to power city buses? 

• Short full refuelling times – this is one of the key strengths of hydrogen buses and a very big advantage over strictly electric-based vehicles. A hydrogen bus (FCEV – Fuel Cell Electric Vehicle) takes on average around 15 minutes to refuel, while a battery bus (BEV) can require up to several hours to recharge (with plug-in chargers). 
• Good range – advocates of hydrogen buses point to their high efficiency. Using hydrogen fuel cells, the bus may be able to cover up to 400 kilometres on a single fill-up. 
• Low-emission – a very important issue in the context of the continuing interest in modern hydrogen-powered city buses is their environmental credentials. Assuming they use so-called green hydrogen (hydrogen produced by electrolysis of water using renewable energy), their operation does not involve CO2 emissions, making them zero-emission vehicles. However, even in the case of the use of so-called grey hydrogen (hydrogen produced by reforming natural gas or other hydrocarbons derived from oil refining), we can talk about the low-emission performance of the buses using it. In the course of the operation of hydrogen cells, besides electricity, only heat energy and water are produced. 
• Safety – a properly designed hydrogen bus is a vehicle that is not only environmentally friendly and economical but also safe. This is due, among other things, to the properties of hydrogen itself, which is much lighter than air and has a high auto-ignition temperature in air of 585°C. This is significantly higher than, for example, petrol, which has an auto-ignition temperature of around 215°C. The lightness of hydrogen means that, in the event of a leak, it instantly becomes airborne, thus reducing the risk of ignition. The high auto-ignition temperature in the air, on the other hand, makes it difficult to initiate the combustion process of hydrogen with air without additional agents, which is important in terms of safety in the event of a collision. 
• Low-temperature efficiency – hydrogen buses do not experience a drastic reduction in driving performance at lower temperatures. 

There are also other reasons why more and more urban centres are choosing to invest in hydrogen buses. Worth mentioning in this context are: 

• the low noise and vibration levels generated by this type of public transport, 
• no load on the local power grid, 
• various subsidy programmes to support the hydrogen transition of public transport in the area. 

How does a modern hydrogen bus work? 

Many people do not realise that hydrogen buses are essentially electric vehicles. They use hydrogen fuel cell kits to produce electricity. The by-products of this process are only heat energy and water. The electricity generated is channelled into the bus’s propulsion system and, in the case of many models of these vehicles, into a battery. The purpose of such a battery is to provide support to the hydrogen fuel cells when there is an increased energy requirement of the electric vehicle. Figuratively speaking, then, modern hydrogen buses are in fact electric vehicles with their own ‘mini-electric power plants’ on the roofs. 

What is the principle behind the hydrogen cells used in buses? 

To better understand how a hydrogen bus works, it is worth discussing the operation of the hydrogen fuel cell, which is used to produce the electricity that powers the propulsion system of this modern vehicle. The hydrogen fuel cell consists of three basic components, which include: 

• anode, or negative electrode, 
• cathode, or positive electrode, 
• proton exchange membrane separating the cathode and anode – often in the form of a polymer electrolyte. 

The hydrogen fuel cell uses a reverse electrolysis reaction involving oxygen from the air and hydrogen supplied from tanks mounted on the bus. It allows electricity to be generated while the vehicle is in use, producing only heat and water vapour, which is removed to the outside. As a result, no harmful substances are produced. This allows the hydrogen bus to be called emission-free. The electricity produced goes to the vehicle’s propulsion system and to the battery that supports the cells in the event of higher energy demand. 

What is the mechanism of the hydrogen bus? 

How is a set of hydrogen cells able to power a modern bus? It is a multi-stage process that is worth analysing in detail. 

1. The stage that initiates the whole process of energy flow in the vehicle is the supply of oxygen to the hydrogen cell in the form of air purified by special filters and hydrogen from tanks usually located on the roof of the vehicle. The hydrogen is transported to the anode, while the oxygen is transported to the cathode. Importantly, the surfaces of both electrodes are coated with a catalyst. 
2. Hydrogen fed to the anode initiates a reaction with the catalyst. Its oxidation occurs, causing it to decay into electrons and protons in the form of hydrogen cations. 
3. The proton exchange membrane only allows protons to pass through it, which pass to the cathode side, while it blocks the flow of electrons resulting from the decomposition of hydrogen. 
4. Electrons from the oxidation of hydrogen are directed to the cathode by an external electrical circuit, creating a current that is used to drive the bus’ electric motor. 
5. When the electrons are transported to the cathode, they bind to the oxygen there and are reduced to oxide anions. 
6. Protons resulting from the oxidation of hydrogen pass to the cathode through the membrane, where they react with oxide anions to produce water and heat energy. 

The electricity generated by the hydrogen fuel cell kit is supplied to the bus’s electric motor, as well as to the traction battery that acts as a booster. With the electricity produced, the vehicle can move. As a by-product of the cells’ operation, water and heat are removed to the outside. 

Hydrogen buses in Poland – what is the current situation? 

As a result of investments made in recent years, Poland is slowly becoming an increasingly important player in the European hydrogen bus market. The number of Polish cities served by carriers adding more hydrogen fuel cell buses to their fleets is increasing. Among the vehicles being tested and implemented in our country are hydrogen buses from foreign concerns such as Mercedes, for example, as well as from Polish companies. Crown examples of domestic hydrogen bus models include the NesoBus, produced at the newly established Świdnik plant, as well as the Solaris Urbino 12 Hydrogen. 

The NesoBus brand was established as an initiative belonging to the Polsat Plus Group of companies and ZE PAK. The signature bus was designed from the ground up as a hydrogen construction powered by green hydrogen, which makes it an emission-free solution. It is characterised by, among other things: 

• impressive range – up to 450 km, 
• short refuelling time – up to 15 minutes, 
• high efficiency – it can run without refuelling for up to 2 days; it consumes on average about 8 kg of hydrogen per 100 km and its tanks hold 37.5 kg of hydrogen, 
• satisfactory capacity – accommodates up to 93 passengers, including up to 37 seated, 
• the high quality of the hydrogen fuel cells used, sourced from the leading supplier of this type of solution, Ballard, 
• the robustness of the hydrogen tanks – particularly important in terms of vehicle safety – supplied by the specialists in this field, Hexagon, 
• an ergonomic, modular design, which allows components of the entire hydrogen system to be replaced in the future with other, better-performing components, 
• construction based on the use of modern, lightweight materials and efficient air-conditioning and heating systems – contribute to a reduction in the need for electricity as well as fuel consumption in the form of hydrogen, 
• modern design, which was the responsibility of Torino Design, a company with extensive experience of working with the automotive sector. 

Also worth noting is the evocative name of the NesoBus, the first four letters of which are derived from the phrase: “No Exhaust Emissions, Cleanses (the air)”. It derives from the fact that this Polish hydrogen bus contributes to the elimination of emissions of harmful substances, including carbon dioxide, nitrogen oxides and particulates, in particular fine PM 2.5. Rybnik, for example, has already decided to implement NesoBuses in its public transport fleet, and in time it will also be possible to see them in Gdańsk or Chełm, for example. 

In the field of industrial hydrogen bus design and production, Solaris Bus & Coach is also highly successful. This is borne out by data which shows that this manufacturer’s share of the European hydrogen bus market was as high as 44.5 % in 2023. Polish hydrogen buses Solaris Urbino 12 Hydrogen are an important element of public transport in more than 20 towns and cities located in various countries of the Old Continent, including, among others, the Netherlands, Italy, Germany, Austria or Sweden. In Poland, this model can be found, for example, on the streets of Konin or Poznań. On board the Solaris Urbino 12 Hydrogen, 85 passengers can travel in comfort and safety, including 37 in seating positions. 

It can be said with full conviction that the Polish hydrogen bus ‘has more than one name’. Polish companies such as Autosan, Arthur Bus and Pilea, among others, are also involved in the production of this type of modern means of public transport. Local authorities are encouraged to invest in hydrogen-powered buses through various subsidy programmes, including, among others, Green Public Transport, operated by the National Fund for Environmental Protection and Water Management (NFOŚiGW). Other initiatives are also worth mentioning, such as the subsidies offered by the Centre for EU Transport Projects. 

In doing so, it should be noted that for the development of public transport based on hydrogen cells, it is not only necessary to invest in the fleet but also in the appropriate infrastructure. This includes, among others: 

• hydrogen filling stations – such places already exist, e.g. in Poznań, where near the Miłostowo tram terminus there is a publicly accessible 24/7 hydrogen filling station with three dispensers, set up by Orlen, 
• plants for the production of green hydrogen, which would be able to meet the market demand for this element, 
• transport infrastructure to ensure the efficient movement of hydrogen from the production site to the individual filling stations. 

Harnessing the potential inherent in hydrogen buses requires systemic action and large financial outlays, but the benefits – both in the short and long term – make this the right direction for Poland to take. 

Hydrogen buses – an important part of the modern urban fabric 

Modern city buses using hydrogen fuel cells combine three aspects that can be summarised as ‘3 x E’: 

• ecology, 
• economics, 
• ergonomics. 

On the one hand, they are low- or – in the case of using green hydrogen – zero-emission electric vehicles whose only by-products are water and heat. On the other hand, they are characterised by good range, high efficiency and short charging times, making them financially viable in the long term. A third, and equally important, is the high level of comfort they provide for the passengers who move with them, including those with disabilities. It is therefore no surprise that an increasing number of Polish cities aspiring to be modern, climate-neutral and friendly to their inhabitants have innovative hydrogen buses on their streets. 

Designing vehicles based on hydrogen technology, such as modern city buses equipped with hydrogen cell kits, for example, requires a very high level of interdisciplinary competence from the specialists involved. At Endego, we have many years of experience in leading and implementing technology projects in cooperation with bus manufacturing companies. As part of our comprehensive services, we provide active support at every stage of the respective project: from the development of the initial concept to the start of series production. 

Are you planning the design of a modern green energy city bus and need the support of qualified engineers and designers to realise this ambitious project? Get in touch with us! 

If you would like to learn more about the technology projects we have completed for bus manufacturers, we encourage you to read another article on our blog: Endego: A revolutionary approach in bus design. 

One significant cause of road accidents and collisions is driver distraction. The large number of stimuli reaching the driver makes it difficult to concentrate, and often all it takes is a moment’s inattention for a tragic event to occur. The ADDW system, a system that constantly monitors the driver’s attention, is designed to remedy this problem. How does it work?

The ADDW system uses technology based on infrared and cameras aimed at the driver’s eyes to verify that he or she is focused on the road under certain conditions. As a standard, it is supposed to activate when the vehicle exceeds a speed of 20 km/h, but the car manufacturer can also adopt a lower threshold for the initiation of this solution. If the set speed is exceeded, the ADDW system will initiate calibration and then monitor the driver’s vision for three areas of the visual field. These include:

• roof, as well as looking to the side,
• looking forward and sideways from the front (this is the behaviour expected of the driver),
• looking below the line of the windscreen.

The ADDW system is particularly sensitive to the driver looking at the passenger’s lap and foot area – this is because it is usually a signal that the driver is using a mobile phone while driving.

The ADDW system’s task is not only to monitor the driver’s attention, but also to react when a loss of concentration is recognised. A warning signal in the form of an audible, visual or vibration will start to be emitted and increase in intensity if:

• the vehicle reaches a speed of between 20 km/h and 50 km/h and the driver looks below the windscreen line for more than 6 seconds,
• the vehicle exceeds a speed of 50 km/h and the driver looks below the windscreen line for more than 3.5 seconds.

The alarm signal will automatically switch off once the driver’s gaze is directed to the correct area. It is also worth adding that:

• not only the driver’s gaze is monitored, but also the position of his or her shoulders and head – to counteract the phenomenon of falling asleep at the wheel,
• the ADDW system is designed to operate both during the day and at night, thus providing round-the-clock protection.

ISA (Intelligent Speed Assistance) – Intelligent Speed Assistant

Another important car safety system that falls under the umbrella of ADAS, or advanced driver assistance systems, is the intelligent speed assistant. The purpose of this system is to force the driver to comply with the speed limit adopted for a given stretch of road. What is the operating model of the intelligent speed assistant?

To carry out its tasks, the intelligent speed assistant uses information from either the traffic sign recognition system or the GPS system (or both). The ISA system can function in the car in one of two versions:

• passive – the system only informs the driver that the speed limit has been exceeded, using an audible or vibrating signal for 5 seconds,
• active – the system intervenes in the car’s speed, lowering it to the applicable limit for a given distance by reducing the vehicle’s engine power.

The use of ISA as a car safety system is justified by the fact that a large proportion of road collisions and accidents are due to cars not travelling at the speed limit.

Object detection systems when reversing

Object detection systems for reversing are important solutions for the safety of the vehicle, the occupants and the environment. Their purpose is to prevent collisions with people and objects behind the vehicle. Parking sensors and reversing cameras have been used in vehicles for many years. However, this does not mean that there is a lack of innovation in this area. What are some other, even more modern safety features in the car to support the driver during the reversing manoeuvre?

• Cross traffic monitoring system when reversing

A major support for the person driving the car in reverse is the system that monitors cross traffic when reversing. It provides a wider range of possibilities than a standard rear-view camera with parking sensors, enabling the identification of cars and pedestrians approaching the car from the left or right. This system is a valuable convenience in many everyday situations, such as when reversing out of a parking space onto the carriageway. It detects oncoming cars or approaching pedestrians and issues a warning signal, making it possible to avoid a collision.

• Brake assist when reversing

One of the most innovative safety systems to support drivers when reversing a car is the reversing brake assistant. Its main purpose is to detect approaching objects before the driver can see them. The system is already activated when the driver engages reverse gear. Using information from rear-mounted sensors, the system informs the driver of the position of an object behind the car when a hazard is detected. If the driver ignores the received alert, the reversing brake assistant applies the brakes and stops the car to avoid a collision with the detected object.

ACC (Adaptive Cruise Control) – active cruise control with automatic speed control

The use of active cruise control increases both the driving comfort of the car in question and the associated safety level. It automatically adapts the car’s speed on an ongoing basis to changing road conditions and to settings set by the driver, such as the minimum distance to be maintained from other vehicles. ACC maintains a safe distance between the vehicle and other vehicles ahead. When they slow down, the cruise control makes the car brake, and when they accelerate, it increases the speed of the vehicle.

It is worth noting that ACCs for cars with manual gearboxes are only able to reduce the speed of the vehicle to a certain limit and require driver intervention. In contrast, the latest active cruise control systems fitted to new cars with automatic gearboxes make it possible, for example, to stop the vehicle in front of traffic lights and set it in motion at the appropriate moment.

EDR (Event Data Recorder) – automotive black box

According to EU regulations, from 7 July 2024, every vehicle manufactured in the EU must be fitted with a so-called in-car black box, or EDR system. Its task is to continuously record various parameters of the car’s operation, with the data it collects being continuously overwritten so that the device’s memory is sufficient to record the values of specific parameters, such as vehicle speed, driver reaction time or seatbelt status, among others, during an accident. The signal to start recording and saving data is the detection of a dangerous traffic event by the ACM system’s sensors.

The in-car black box records and saves data on events that occurred up to five seconds before, during and up to 250 milliseconds after an accident. The information it collects can be useful for, among other things:

• reconstruct the course of the traffic incident in order to clarify its causes and assess the driver’s attitude during the legal proceedings,
• analyses carried out by accident and collision investigation bodies and aiming to improve road safety.

It should be noted that the data recorded by in-vehicle black boxes is anonymous and can only be used in legally justified cases, with the consent of the vehicle owner.

In addition to the state-of-the-art car safety systems outlined earlier, there are many other solutions to enhance the protection of car occupants and other road users, among them:

• the Tyre Pressure Monitoring System (TMPS), which is responsible for verifying the tyre pressure status and keeping the driver informed of any irregularities,
• AFS (Adaptive Frontlight System), an adaptive front-lighting system that adapts to road conditions to make the car safer when cornering, for example,
• the eCall system, a pan-European rapid alert system for road accidents that allows for both automatic and manual emergency calls to the relevant services.

Car safety as a priority for automotive designers

Modern car safety systems are one of the top priorities for designers working on behalf of automotive companies. Ongoing work is being done both to improve long-established solutions, such as ABS and ESP, and to develop new safety systems, such as lane assist, AEB and reversing detection systems. Initiatives in this area result both from autonomous decisions by manufacturers, who are keen to increase the attractiveness of their vehicles, and from the introduction of legal regulations, obliging car corporations to implement specific solutions in their products to improve their safety.

Designing a car for safety is a complex field that requires the professionals involved to have extensive experience and a high level of competence in many areas. A comprehensive approach to technological design also proves to be essential, which is the key to developing reliable, effective solutions. At Endego, we offer professional support from qualified engineers and designers who have many years of experience in leading and implementing technology projects for companies in the automotive sector.

A few words about Altair Technology Conference Poland

Altair Technology Conference is a periodic conference organized worldwide
in cooperation with Altair Engineering – a global technology company providing solutions in the areas of design and simulation, data analysis and AI, and high-performance computing (HPC). ENDEGO, as an authorized partner and official distributor of Altair software in the domestic market, has been a co-organizer of the Polish edition of this event since the beginning.  

ATC Poland is a unique event that brings together those who use HyperWorks and Inspire packages on a daily basis, as well as those interested in new technologies and numerical analysis topics. Participants have the opportunity to learn about the latest tools, technologies, and working methods, as well as listen to inspiring presentations and speeches in the field of simulation delivered primarily by practicing engineers.

The rich program of Altair Technology Conference Poland

Many participants of the meeting noted the exceptionally rich program of the conference, which included:

• More than 20 lectures were given by representatives of industry research and scientific institutions, during which practical applications and capabilities of Altair software were presented.
• a lecture by special guest Lukasz Baek from the CaroSeries channel, who talked to participants about the future of motoring, with a special emphasis on electrification and driving autonomy.
• a unique opportunity to see “live” the ElipSafe mobile energy shield, designed by Wimed in cooperation with Endego in Altair software. The device was presented in two views – before and after the crash.
• networking sessions.
• A joint dinner for all event participants.
• A unique hands-on workshop for 60 people, conducted on specially prepared workstations allowed participants to become familiar with the latest version of Altair software.

In the hotel’s foyer, where coffee breaks were held, it was possible to learn about the complementary solutions offered by the conference partners: workstations from Lenovo and 3D navigation products from 3Dconnexion. In the same space, there were also computers available to learn about selected Altair software.

Exceptional networking atmosphere

Altair Technology Conference Poland 2024 not only provided participants with knowledge and new skills but also created a fantastic space for networking. Coffee breaks provided the perfect moment for informal conversations, which often turned into inspiring discussions about current projects, challenges, and opportunities for collaboration. In a relaxed atmosphere, it was possible to discuss topics that there was not always room for in formal presentation sessions.

The evening dinner was also particularly valuable. Participants had the opportunity to get to know each other better and establish closer relationships. The atmosphere was conducive to building trust and openness, which is crucial for long-term cooperation. Table conversations were passionate and engaging, with participants sharing their successes and challenges, which often led to the exchange of valuable tips and advice.

These moments proved to be extremely valuable for building professional relationships and cooperation between different industry sectors. The contacts established may result in future joint projects, innovative solutions, and mutual support in professional development.

Thanks

We would like to thank all the speakers for their valuable presentations and the participants for their active participation in the conference. Your commitment and substantive contributions were crucial to the success of this event.

We also extend our gratitude to our partners Lenovo and 3Dconnexion for their support and cooperation, which contributed to the high level of organization of the conference.

Special thanks go to Altair for co-organizing this unique event.

Conference materials

Please be advised that we will be reminding you of individual presentations from ATC Poland shortly. We encourage you to follow our Facebook and LinkedIn profiles to stay up to date with the latest news and events.

See you at the next edition of Altair Technology Conference Poland!

The surveys conducted during the conference show us that Altair Technology Conference Poland 2024 met the expectations of the participants. We hope that you found our conference a source of inspiration and practical tips for further professional development.

We already invite you to participate in future editions and other events organized by Endego. Thank you for your presence and see you at future conferences!

We encourage you to browse through the photo gallery from Altair Technology Conference Poland 2024 to feel the unique atmosphere of the event again.

Currently, car crash tests are conducted not only by the manufacturers but also by independent organizations such as the European New Car Assessment Programme (Euro NCAP). Depending on the entity that conducts the crash tests, their list and the parameters tested may vary, although the aim is to subject vehicles to the most comprehensive verification and evaluation of the resilience and safety provided to the driver and passengers both in a crash and in standard use. Over the years, crash test technology has been evolving – this has increased the quality and reliability of such tests and has also resulted in more intensive efforts by car companies to improve the safety of their cars and to search for new and better materials that will provide more effective protection for car users.

The remainder of this article will explain, among other things, what exactly car crash tests are, the basic types, how they are conducted, and what innovations in crash test technology and materials to enhance vehicle safety we have seen in recent years.

What are car crash tests?

Almost every day we receive information about car accidents that occurred on Polish or foreign roads. The first such fatal event occurred as early as 1889 in Great Britain, and by the 20th century, fatal accidents had become a tragic part of the reality around us. With the development of automobile traffic, more and more emphasis began to be placed on the issue of vehicle safety, which is now an absolute priority for the entire automotive sector. Natural consequences of this trend include:

• the development of crash test technology and regulations in this area,
• increased efforts by automakers to find new materials and technologies that can improve the safety and durability of the vehicles they produce,
• increased awareness of car users themselves, who are not only guided by the safety aspect when choosing a new car but are also interested in solutions, such as the crash test simulator, aimed at raising awareness of the risks associated with car crashes and accidents and promoting responsibility “behind the wheel.”

In the process of increasing the safety level of cars, a huge role is played by car crash tests (crash tests). In the simplest terms, these are specially designed tests carried out under strictly defined conditions, which are designed to mimic as closely as possible specific traffic situations, such as collisions or accidents. These tests may examine not only the vehicle’s behavior under the impact of certain forces on it, but also the effects of this impact on drivers, passengers, or pedestrians, for example. It is worth noting that the methods used for specific tests differ not only because of the type of simulated traffic situation or the entity conducting the tests but also, among other things, because of the type of vehicle. For example, crash tests on trucks will differ from those on passenger cars, just as tests on internal combustion vehicles may differ from those on electric cars.

What are car crash tests for?

There are various reasons that new cars undergo crash tests. The primary reason is the desire to verify the safety and resilience of manufactured vehicles before they are put on the market. Detection of imperfections allows necessary changes to be made to the design or manufacturing technology to improve the level of car durability and the protection it provides to the driver and passengers.

Another reason that determines the important status of car crash tests is legal regulations. These require auto manufacturers to test their vehicles to meet certain crash standards. Failure to meet these standards prevents the tested car from being allowed to operate in the country where the regulations apply.

An important motivation behind independent entities that specialize in conducting car crash tests is to make potential users of specific models aware of how they perform in terms of safety. For example, thanks to the stars awarded by Euro NCAP, a person interested in purchasing a vehicle can verify that the car he or she has been considering is capable of providing him or her and his or her family with an adequate level of protection while on the roads.

How are car crash tests conducted?

Independent institutions are usually responsible for conducting crash tests. One of the most important entities with this profile is the Euro NCAP – European New Car Assessment Program, whose tests are carried out on cars of many popular brands. By familiarizing yourself with the characteristics of basic car crash tests performed by this institution, you can better understand what crash testing is all about.

One of the basic tests Euro NCAP subjects the vehicles it tests to is the off-set (front impact) frontal crash. It includes two separate tests:

• the first test involves a full frontal impact with a stationary wall at a speed equal to 50 km/h.
• the second test involves a vehicle colliding with a mobile obstacle weighing 1,400 kg. This choice of obstacle parameter is intended to mimic the average car with which a collision on the road can occur. Two details are important in this case: the speed of movement of the car and the obstacle is equal and is 50 km/h, and the impact area is 50% of the front surface of the vehicle.

Another test carried out by Euro NCAP is the side impact test. In this case, the test involves hitting a 900 kg barrier against the side of a stationary vehicle at the level of the center body pillar. The barrier moves at a speed of 50 km/h during this test.

An important part of the set of tests conducted by Euro NCAP is the pole test (field test). What does it consist of? During this test, the car travels sideways at 29 km/h and then hits a vertical obstacle at the level of the center body pillar.

Among the Euro NCAP tests, the pedestrian impact test was also not to be missed. During this test, a pedestrian is simulated to be hit by the front of the car at a collision speed of 40 km/h. The pedestrian’s role in this case is played by a specially constructed dummy, which imitates the figure of an adult or child.

It should be noted that the above four tests do not exhaust the pool of all tests that new vehicles can undergo. Crash tests can also create simulations of many other situations, such as roofing, driving into a tree, or driving a car into the back of another car, among others. What’s more, institutions such as Euro NCAP also subject cars to other tests that allow a reliable assessment of their safety. As examples of such tests, we can cite, among others:

• test of child safety systems,
• a test of speed assistants and unfastened seatbelt reminder systems,
• test of automatic braking systems,
• test of vehicle stabilization control systems,
• a test of systems that examine driver fatigue and distraction.

But returning to the basic set of crash tests conducted by Euro NCAP, the cars subjected to them are evaluated by awarding the appropriate number of stars (scale from 1 to 5). It is worth noting that the institution is aware of the continuous development of crash tests – it takes an active part in them – so the ratings it awards to individual car models are not “eternal” – after six years they reach the statute of limitations. From what angle are cars taking part in Euro NCAP tests evaluated? Several areas are evaluated on a percentage basis, which include:

• protection of adult passengers,
• child protection,
• Protection of other road users,
• assistance systems.

The sub-ratings later translate into an overall number of stars awarded to the tested car model.

Innovations in crash testing

The dynamic development of the automotive sector and the associated increase in the safety level and vehicles’ durability means that car crash tests must also evolve and constantly “raise the bar” for the cars being tested. This is also dictated by successive regulations aimed at increasing the safety of road traffic and its participants. Institutions specializing in conducting such tests are constantly working on developing testing technologies, modifying both the methods and types of tests themselves, as well as adding more factors to be verified and evaluated. What examples of innovations in the area of car crash tests are worth paying special attention to?

Numerical models representing the human body

Surrogates of the human body or crash dummies designed to simulate passengers, play an important role in car crash tests. This is one area where particular development potential is seen in terms of improving crash-tests and enhancing their usability. Developments in this area involve not only the design of the dummies themselves, but also, for example, numerical models mapping the geometry and properties of specific parts of the human body. One initiative worth noting was the European Union-funded THOMO project to develop a numerical model of the human chest, that is, the entire area between the head and abdomen. The results of the research carried out as part of this project have led to a better knowledge and understanding of the responses of human bodies with different physical parameters to the forces acting on them during crashes, which in turn has fueled the development of work on crash dummies with better biological fidelity.

Mannequins simulating the female figure

An interesting example of innovation in crash testing, which takes into account a factor that has been downplayed for years, are mannequins that simulate the female figure. For a long time, such models of the human body were usually based on the parameters and body structure of the average male. Meanwhile, it is estimated that today about half of the drivers are women, who are not only smaller and lighter on average than men, but also characterized by, among other things, different muscle strength or shape of the torso, pelvis, and hips. All this makes their bodies react differently to the stresses they face during dangerous traffic incidents.

This is perfectly evident in low-force rear-end collisions, one of the more common types of collisions on the road. Studies show that in such collisions there is a significant difference in the disadvantage of women in terms of the level of risk of cervical spine injury. The group of Swedish specialists conducting this research, led by Astrid Linder, has developed a special dummy that replicates the body of an average woman. It is being used in crash testing, and it is possible that it will contribute in the near future to a greater focus by auto manufacturers on testing their vehicles for the safety provided to women. Currently, some car companies, such as Mercedes-Benz, have already been using dummies simulating a woman’s body in crash tests of the vehicles they produce for years, but due to the lack of relevant legal regulations, this is not a fully common practice in the automotive sector so far.

Classic solutions instead of touch screens

Over the past few years, automakers have been eager to expand the range of features in their vehicles that required activation using touchscreens and surfaces. This was intended not only to modernize the design of car interiors but also to increase driver convenience and reduce production costs. However, according to Euro NCAP specialists, the trend associated with the move away from traditional buttons and switches to touch-sensitive solutions has in practice contributed to greater distraction for drivers, and thus an increase in the risk of accidents. For this reason, already in 2026, a mandatory condition to allow a new car model to contend for the maximum number of stars in Euro NCAP crash tests will be the use of manual switches, levers or buttons that operate a minimum of five important functions, such as operation:

• turn signals,
• emergency lights,
• windshield wipers,
• horn,
• emergency call function.

Virtual car safety tests

There is no denying that more and more areas of our lives are in some way entering the virtual world. The same is true in the automotive sector – industrial design of cars is based on CAE analysis or parametric CAD modeling, among others, and actual crash tests are supported by advanced simulations. Virtual car safety tests bring many benefits related to, for example:

• reducing costs – virtual car safety tests reduce the number of actual crash tests, thus reducing losses associated with damaged vehicles, among other things,
• the ability to analyze various factors in detail – thanks to simulations, it is possible to check how given components will behave under specific parameters, as well as under the influence of set forces or other factors acting on them, which in turn allows you to refine individual components of the car until the optimal form is achieved,
• ecology – a reduction in the number of actual crash tests is also associated with less waste production in the form of parts of damaged cars,
• the safety of conducting the test – any real vehicle collision, even implemented under controlled conditions, carries a certain risk to the environment, including the measuring apparatus, which is not present in the case of virtual safety tests.

Toyota engineers, who are the authors of the THUMS (Total Human Model for Safety) system, are taking an active part in the dynamic development of virtual car safety tests. This is a continuously improved virtual crash system, commonly referred to as digital or virtual dummies, which allows the creation of various digital models of the human body characterized by a very high accuracy of biological reproduction. The model developed with its help can reflect not only the assumed size or shape of the human body but also, among other things, the position, density, and sensitivity of muscles, bones, and organs. What is noteworthy, with THUMS it is possible to prepare, for example, a model of a child, pregnant woman, or senior citizen, and then track and analyze data from about 20 million points on the body and inside the body of such a virtual “passenger.” Using such a model, engineers have the ability to analyze the impact of various types of collisions and accidents on specific organs of the “passenger,” taking into account how tight his muscles are. We are not able to carry out such a thorough study on the basis of – even very modern – conventional crash dummies.

What modern materials are used to make safe cars?

Auto manufacturers striving to increase the level of protection their vehicles provide to drivers and passengers are constantly working on exploring new and improving already-known materials used to manufacture various automotive components. What materials are worth paying special attention to in terms of car safety and durability?

High or ultra-high-strength steel

One of the most widely used material groups in the automotive industry is steel. This is due to a number of advantages of these materials, which include high strength or excellent energy efficiency. Of course, steel is not equal to steel, which is why automotive components responsible for passenger safety, which must have particularly good strength properties, are primarily used:

• high-strength steels, such as BH or HSLA – are used for, among other things, thresholds, floors, side posts, and other components that contribute to controlled crush zones,
• ultra-high-strength steels, such as AHSS – like BH or HSLA, are used in the production of automotive parts crucial from the perspective of passenger safety, while their additional advantage is that they can contribute to reducing vehicle weight (exceptional strength allows the use of thinner sheet metal).

Plastics

It is difficult to imagine today’s automotive world without strong, durable and lightweight plastics. They are used both in the manufacturing of exterior automotive components, such as spoilers and bumpers, and for the production of interior car equipment, such as headliners, carpets and headrests. Which plastics are particularly popular for components that play an important role in the context of car safety? Among them are:

• polyphenylene sulfide (PPS), is used, for example, in the manufacture of pumps, valves, and various fuel system components critical to the safe operation of autos,
• polypropylene with EPDM, used, for example, in the manufacture of heavy-duty bumpers,
• foamed polypropylene (EPP), used to make components designed to absorb energy, such as in car doors.

It is worth mentioning that components made of plastic are often reinforced by so-called reinforcement with various types of metallic or ceramic fibers, which further improves their mechanical characteristics.

Composites

Another important group of materials being considered in the process that is designing a car are composites. An excellent example of an innovative composite used, among other things, for body components or drive shafts, is carbon fiber. It is characterized not only by high strength, but also by its lack of susceptibility to corrosion, very low weight or unique aesthetics. Another composite material eagerly used in the automotive sector is Kevlar, or aramid fiber, which offers even better strength properties, as well as high thermal and friction resistance and extremely low weight. Due to its qualities, Kevlar is used to reinforce timing belts and other important parts of the car’s structure.

Safety vs. car design

Increasingly demanding crash tests, as well as the desire to provide customers with high-quality, safe vehicles while maintaining cost-effective production, are influencing the multi-stage car design process. Among other things, computer analysis and simulation now play a large role in it, and are used both when designing individual car components and the entire vehicle. Focusing on the optimization of individual automotive components and then correctly implementing the best version of them in the design of the car is very important in the context of the vehicle being able to provide its users with high safety standards.

Designing and then implementing a safe automotive component with the desired characteristics into production requires a comprehensive approach and the involvement of a qualified team of engineers in a given technology project. As Endego, we can provide professional support from experts with many years of experience in leading and implementing technology projects for the automotive sector. We provide comprehensive engineering services, where we actively participate in all phases of the project – from the preparation of the initial concept to the start of serial production.

Would you like to enlist the help of competent engineers and designers to support you with components that can contribute to a marked improvement in the safety of your company’s project car? Get in touch with us!

What innovative materials represent the future of car manufacturing? 

Car manufacturers wishing to implement environmentally friendly production standards in their plants must follow the principles of eco-design and circular design. According to these, car manufacturing should aim to reduce the environmental cost of vehicles by, among other things 

• reducing their weight, 
• the use of recyclates and renewable materials in their manufacture. 

Car manufacturers are working intensively on innovative materials that can prove themselves in the vehicle manufacturing process, while also meeting the relevant criteria. One aspect that receives particular attention in the search for new materials for car manufacturing is their lightness. At the same time, they should be able to meet other requirements, such as durability or optimal manufacturing costs. 

In the context of caring for the well-being of the environment and reducing the overexploitation of primary raw materials, increasing the proportion of recyclates and renewable materials in car manufacturing plays an even more important role. This is reflected in the regulations that car companies are subject to, which oblige them to include recycled materials in the design of their vehicles. This is intended to lead to more sustainable car manufacturing, a reduction in the amount of waste generated and greater independence of the automotive sector from the need to source virgin raw materials. 

Modern car manufacturing – why are we aiming to reduce the weight of cars? 

When we delve into how car production is changing around the world, we can see some interesting trends. The first trend is that the cars hitting the market are getting bigger and bigger. If we compare, for example, current B-class cars with their counterparts from a few decades ago, we can see that the size of many contemporary representatives of this segment exceeds that of similar older vehicles. Another process, which can be easily observed, is the expansion of car equipment. Air-conditioning or advanced safety systems have become a standard that was not commonplace just a dozen or so years ago. What is particularly interesting, however, is that modern car manufacturing is moving towards increasing the size of cars and extending their equipment, while at the same time placing increasing emphasis on reducing their weight while maintaining an appropriate level of other parameters. What are the reasons for this phenomenon? 

The primary reason why companies seek to ensure that their car manufacturing process incorporates the use of modern, lightweight materials is practical. The increase in vehicle weight, a consequence of, among other things, the aforementioned factors related to the size and equipment of today’s cars, has a number of negative consequences. These include: 

• a drop in fuel efficiency, or in simplest terms, higher combustion, 
• increased emissions of carbon dioxide and other pollutants into the atmosphere, 
• a reduction in car performance. 

So, in a bid to achieve better performance and fuel efficiency while reducing harmful exhaust emissions, manufacturers are seeking to reduce the weight of the cars they produce. This involves looking for new, lighter materials that can be used to produce components with similar or even better properties than their traditional, heavier counterparts. 

What modern materials are used to reduce vehicle weight? 

Replacing heavier materials with lighter ones is not new in car manufacturing. This trend has been evident for years, as evidenced by the increasing use of plastics and composite materials in the vehicle manufacturing process. An important challenge facing automotive companies planning the design of a car and its subsequent production is finding the right balance between reducing the weight of the vehicle and maintaining its key properties. 

The scale of the difficulty of this task can be well illustrated by the properties of steel and aluminium alloys used in automotive construction. The attractiveness of aluminium alloys for the production of car body components, for example, is primarily due to their light weight, in which they are superior to steel. The weight aspect, however, has not led to the abandonment of steel for automotive components. The reason is its higher deformation resistance than aluminium alloys. In order to reduce the weight of steel components, for example, they are made from low-carbon steel with the appropriate admixtures, which makes it possible to use thinner, and consequently lighter, sheets while maintaining the expected level of strength. 

Plastics

Undoubtedly an important group of materials with which the weight of a vehicle can be reduced are various types of plastics. They offer an advantage both functionally and economically. What are some of the lightweight plastics used in car manufacturing in Poland and worldwide? 

Based on the example given, it can be concluded that modern industrial design of cars is moving towards weight reduction. The aim is to improve the fuel efficiency and performance of vehicles and reduce their exhaust emissions. At the same time, it should be noted that reducing the weight of cars must not be associated with a deterioration of their other properties. Innovative materials can be used to make vehicle components that are lighter, have high strength and look good in a variety of other ways. Which of these materials are worth paying particular attention to? 

• EPP, or expanded polypropylene, is a lightweight, highly mechanically resistant material, which is most commonly used in the car manufacturing process to create energy-absorbing elements in bumpers and car doors, for example. It is also used in the manufacture of interior car components, such as head restraints or seat and boot panels, among others. It is worth noting that EPP can be successfully combined with a variety of metal components and plastics, giving these materials other desired properties. 
• Polyurethane – the characteristic features of this plastic are high durability, flexibility and resistance to mechanical damage. Exterior automotive components, including spoilers for example, are made from this material. 
• Ultramid – another example of a lightweight plastic that is in high demand in the automotive sector. The attractiveness of this thermoplastic material is not only due to its low weight, but also its high strength, stiffness and heat resistance. Ultramid can be reinforced in various ways, such as with glass fibre. Manufacturers use the material to create a variety of lightweight and highly durable automotive components, including oil sumps. 

Composites 

Composites are also a group of modern materials used in car manufacturing to reduce weight. Among these, carbon fibre is particularly well-known in the automotive world and is used, for example, for body components and drive shafts. Components made of carbon fibre are expensive, but they stand out: 

• very lightweight, 
• no susceptibility to corrosion, 
• high resistance to mechanical damage 
• exceptional aesthetics. 

It is worth noting that carbon fibre is not the only lightweight composite material of interest to the automotive sector. Another example of a lightweight composite that is used in the automotive industry is aramid fibre, more commonly known as Kevlar. It owes its popularity in the automotive world to, among other things: 

• very low inherent weight – aramid fibres are noticeably lighter not only than steel but also carbon fibre) 
• high tensile strength and mechanical damage, 
• high thermal resistance, 
• high friction resistance. 

What applications does aramid fibre find in car manufacturing? They are used for, among other things: 

• construction of body components in lightweight rally cars, 
• reinforcing vital vehicle components, such as timing belts, 
• the development of friction linings with Kevlar fibre to provide more effective clutch protection in sports cars and off-road vehicles.  

Recyclates and renewable materials – the key to sustainable car manufacturing 

The drive to reduce the weight of cars is not the only eco-friendly trend we can observe in the automotive sector. Another direction being pursued by car corporations both because of their responsible approach to environmental wellbeing and the legal regulations that oblige them to do so is circular mobility. Its primary objectives include: 

• reduction in harmful exhaust emissions, 
• reducing the amount of waste generated, 
• reducing the use of primary raw materials in favour of greater use of secondary raw materials. 

The intense discussions at European level surrounding the work on new regulations on the so-called “circularity” of vehicles are justified by the statistical data. According to current calculations, car manufacturing is one of the industries most responsible for the consumption of resources such as steel, plastics, aluminium and rubber, among others. In the context of this industry, there is also a high demand for, for example, glass or copper, and with the advancement of motorisation and the development of electric vehicles, also rare earth elements. The transition of the automotive sector to a closed-loop economy is seen as a way of improving this situation. 

It is worth noting that automotive companies aiming to produce cars in line with the circularity concept need to take a comprehensive approach to this issue. Successful implementation of the principles of the circular economy requires that both the way in which cars are designed, manufactured and treated at end-of-life and the materials used to manufacture vehicles are brought up to appropriate standards. The circular production model is currently being implemented by leading companies in the automotive sector, such as Volkswagen, Mercedes, Renault and BMW, among others.  

A very big part of circular car production is the greater use of recyclates than in traditional vehicle manufacturing models. Modern technologies make it possible to recover recyclates, which can be successfully used in the production of automotive components without the risk of degrading their essential properties. It is worth taking a closer look at interesting examples of the use of recyclates and renewable materials in the manufacture of vehicle components. 

What can recyclates and renewable materials be used for in car manufacturing? 

One of the car companies working on using recycled materials to manufacture car components is BMW. The brand’s new vehicles use a minimum of 20% recycled plastics in the total weight of plastics used in the production of a car. Examples of the use of recyclates and renewable materials in some of BMW’s latest electric car models include: 

• matt lacquers made from renewable raw materials, including bio-waste, 
• Deserttex material obtained from powdered cactus fibres and biopolyurethane, used as a substitute for animal leather in the case of seat upholstery, for example, 
• recycled plastics used in the manufacture of bumpers or windscreen covers, 
• floor covering made from a combination of plastics recovered from, among other things, used fishing nets. 

The BMW Group is of course not the only one to make increasingly bold use of recyclates and renewable materials in the manufacture of components for its vehicles. How are other car manufacturers using such solutions to reduce the environmental impact of their cars? 

Ford uses plastic from PET bottles, nylon or polypropylene liners to manufacture chassis and engine covers, as well as front and rear wheel arch covers for its new cars. An important area of the brand’s pro-environmental activities is also the maximisation of aluminium recycling at its production facilities, thus significantly reducing its demand for virgin raw material. It is also worth noting that the manufacturer uses a variety of renewable materials of plant origin in its production, such as soy foam used for seat cushions, backrests and headrests.  

An interesting solution that Mercedes and its partners have developed is pyrolysis oil, which is partially derived from used car tyres. Combined with certified biomethane derived from agricultural waste, it produces a plastic with very good properties, which can be used to manufacture a variety of components such as exterior door handles. The ability to make components from secondary raw materials that do not differ in quality and technical parameters from their counterparts made from so-called virgin plastic eliminates the need to use raw fossil resources. It is worth noting that this recycled material can be used to manufacture other automotive components, including, for example, the impact absorber that is part of the front belt of a vehicle. 

Examples of the use of modern recyclates, renewable materials and other types of recycled raw materials in the production of automotive components can be multiplied. In the context of other applications of these materials that should be highlighted, it is worth mentioning, among others: 

• mounting bracket and other recycled components used on the Audi Q4 e-tron, 
• Dinamica microfibre, derived largely from polyester fibres from, among other things, recycled PET bottles and old textiles, which, in combination with faux leather, was used for the upholstery of the sports seats in the interior of the Audi Q4 e-tron S line, 
• carpets and sound insulation made from recycled materials used in the Skoda ENYAQ iV, 
• interior trim of the ID. Buzz by Volkswagen made partly from recycled materials. 

Summary 

Car manufacturing in Poland and around the world is currently undergoing a gradual transformation towards ecology and greater respect for natural resources. This involves a constant search for new materials that will allow automotive companies to reduce the negative environmental impact of the vehicles they produce while improving their efficiency and performance. 

One of the leading trends in contemporary global car manufacturing is the drive to reduce vehicle weight. What is the reason for car manufacturers to set such a goal? Reducing the weight of a car benefits a number of aspects, such as fuel efficiency and car performance. It also contributes to lower emissions, making the vehicle more environmentally friendly. In order to reduce the weight of their vehicles, car manufacturers are looking for modern lightweight materials that are able to replace heavier counterparts while maintaining the expected level of other properties, such as strength or thermal resistance, for example. Composites in the form of carbon fibre and Kevlar, among others, as well as innovative plastics such as ultramid, are excelling in this role. 

From the perspective of reducing the environmental cost of vehicles, increasing the proportion of recyclates and renewable materials in their construction is more important than reducing their weight. Increasing the use of recycled materials in the car manufacturing process is also a regulatory requirement for car companies. Increasing the use of such plastics in vehicle manufacturing has many benefits, such as reducing harmful exhaust emissions, decreasing the amount of waste generated, and reducing the consumption of primary raw materials, among others. Increased use of recycled materials is also a necessary element for car manufacturing to follow the concept of circular mobility, which is being implemented by an increasing number of leading automotive companies. 

As Endego, we have extensive experience in technology projects for the automotive sector. We offer comprehensive services in which we are involved in every stage of the project, from the development of the initial concept to the start of series production. Amongst others, companies wishing to reduce the weight of their vehicle and use modern recycled materials for their vehicle can benefit from the support of our qualified team. 

Do you need the support of skilled engineers and designers with experience in the automotive sector to help you develop reliable, lightweight components made from recycled and renewable materials for your company’s project car? Get in touch with us! 

In the face of global environmental and sustainability challenges, the off-highway machinery industry is facing the need to adapt to new, more stringent energy efficiency standards. Technological developments and innovations are opening up new opportunities for equipment manufacturers, allowing them to reduce their environmental impact while increasing operational efficiency and lowering operating costs.

Solutions for off-highway machinery manufacturers

With the rapid development of the automotive industry, the availability of solutions to increase energy efficiency is increasing in the off-highway machinery sector as well. However, adaptation to new trends in this case is relatively slow. This is because the simple replication of a single solution for diverse off-highway vehicles is rarely applicable. The selection of the right technology depends on the design, weight, purpose, and use cases or duty cycles, as well as the power and torque requirements of individual machines.

However, there are already a number of solutions that can be used to deliver more energy-efficient off-highway vehicles. We have highlighted some of them below:

• Innovations in design: advances in technology and software make it possible to make changes that increase energy efficiency as early as the concept development stage. The use of accurate computer simulations brings a better understanding of duty cycles and maximizes machine performance while reducing the amount of energy required for operation. In addition, through predictive analysis, potential fault locations and equipment failures can be predicted. By moving away from traditional shapes and using lighter materials, the weight of the vehicle can be reduced, as well as drag and fuel consumption – without sacrificing operational efficiency. The energy efficiency of machines is also influenced by the optimization of drive systems.
• Hybrid drive systems: hybrid solutions combine the efficiency of BEVs with the range of traditional engines, allowing more flexible management of energy consumption. These systems can automatically switch between or combine energy sources, maximizing operational efficiency while minimizing CO2 emissions. The electric motor can successfully support the operation of the combustion engine during braking or acceleration, provide energy for work attachments, or support the temperature control system in the operator’s cab.
• Electrification: more and more off-highway machines with electric drives are appearing on the market. Advances in battery technology, particularly in terms of battery life, charging time, and energy density, are effectively increasing the range of applications for BEV solutions. Off-highway electric vehicles are both greener and quieter than those with internal combustion engines. As a result, the use of BEVs in the off-highway sector reduces fuel consumption and harmful emissions. At the same time, operating costs are reduced, as battery-electric vehicles require less frequent servicing and are cheaper to repair than internal combustion machines.
• Autonomous control systems: more and more vehicles are using automatic management of single functions or entire components. An example of such use is autonomous engine shutdown after a specified period of inactivity, which in practice reduces fuel consumption and noise emissions. With the increasing use of such solutions, remote control of operating functions of off-highway machinery and even its unmanned operation is also becoming popular. In practice, this makes it possible not only to increase energy efficiency but also to improve safety and productivity.
• Adapting business models: technology development is not just innovation in components or design. It’s also new opportunities to offer turnkey solutions such as battery leasing or Vehicle-as-a-Service (VaaS). Their use increases the openness of end users to BEVs, and also makes it easier to finance such machines.

Solutions for off-highway users

Manufacturers aren’t the only ones with a stake in improving the energy efficiency of off-road machines. The energy efficiency of equipment also depends on how it is used and other factors related to fleet management. On their way to reducing the carbon footprint of the equipment they use, users of off-highway machinery can benefit from the following solutions, for example:

• Good planning and innovations monitoring: strategic planning and flexibility are essential to more easily adapt to the latest technologies. By keeping abreast of changing trends and regulations, necessary solutions can be implemented more quickly, gradually increasing the energy efficiency of the entire fleet. This approach saves money in the long term and can contribute to a company’s competitiveness.
• Growing availability of electric machines: with increasing competition and environmental awareness, the attractiveness of battery-powered machines is also growing. More and more manufacturers are choosing to add electric vehicles to their portfolios, making it easier for users to match the most appropriate solution with optimal costs. JCB, Volvo, Wacker Neuson, Mecalac, and Liebherr, among others, already have electric off-highway machines in their portfolio.
• Regular vehicle maintenance: the proper technical condition of machines ensures their optimal operation and contributes to reducing fuel consumption. Ongoing repairs, regular lubrication, and filter cleaning contribute to the correct energy efficiency of the equipment in use. In addition, it is a good idea to use biodegradable oils and lubricants that, in the event of leaks, remain inert to the environment and do not pollute it.
• Education and training: energy transformation is not possible without building employee awareness and involvement. Appropriate use of machinery can significantly increase its energy efficiency and reduce its environmental impact. In addition, when BEV or pHEV technology is used, it is essential to develop competence in the operation and maintenance of electric and hybrid machines. Adequate training allows you to effectively use the latest technologies and take full advantage of their potential. It also builds awareness of the advantages and possibilities of energy-efficient off-highway machinery.
• Digital machine monitoring and fleet management systems: modern technologies, such as telematics and advanced fleet management software, enable precise monitoring and optimization of fuel consumption and equipment efficiency. These systems can identify critical points in fuel consumption and emissions, facilitating efforts to reduce overall energy consumption. In addition, such software is useful for planning and plotting optimal travel routes, which also boosts energy efficiency.

Holistic approach as a tool for increasing energy efficiency of off-highway machinery

The off-highway machinery industry is currently transforming, driven by the need for sustainability and technological innovation. For companies operating in this area, the ability to anticipate trends, flexibility in decision-making, and willingness to invest in new technologies are becoming crucial.

Growing environmental pressures are forcing the off-highway sector to take significant steps toward improving the energy efficiency of machinery. Increasing environmental awareness, supported by increasingly stringent emissions regulations, is opening up unique opportunities for manufacturers to transform the industry in a more sustainable direction. However, in transforming the off-highway industry, it is crucial not only to adapt the design of the solutions offered but also to educate operators and maintain high maintenance standards. The ultimate goal is to achieve harmony between energy efficiency and minimizing the environmental footprint of the entire sector.

Companies that take on the challenge of adapting to the new standards will not only meet market expectations but also contribute to a more sustainable future. These companies have the opportunity to shape the landscape of the entire off-highway sector, leading it toward more efficient and environmentally friendly machine operation.

If you are looking for support in designing energy-efficient off-highway machinery, we cordially invite you to learn more about our experience and expertise in this field and to contact us.

When designing a front grill, care should be taken to ensure both its visual appeal and its functionality. The purpose of this element is not only to decorate the exterior of the vehicle but also, among other things, to protect the radiator from overheating and mechanical damage. So the question is: how should a car grill be designed in such a way that it is an attractive decoration on the one hand, and durable and practical on the other? In this article, we answer questions such as: what exactly do we call a car grill, where is it located, what role does it play in the vehicle, and what is the design process for this element?

What is a front grill?

The front grill, also referred to as a dummy or grille, is one of the essential elements of the car body. Depending on the designers’ intentions, it can take very different forms. One popular type of grille is a grill consisting of an aesthetically shaped frame filled with mesh in a specific shape, such as a honeycomb. Stylish grilles with vertical or transverse, often chrome-plated, elements are also popular.

The grille on a car is usually positioned between the headlights, where it plays the role of a radiator grille. This placement of the grille helps to provide the necessary airflow to the radiator and engine, which aids the cooling process for the hot parts hidden under the bonnet of the car. The use of a grille also protects the engine compartment from contaminants that could contribute to damage and failure. On some models, additional grills are used in addition to the main grille, such as in front of the wheels to cool the brakes, or under the front bumper.

Although the grill on a car has various functional roles, according to many people in practice its visual value is much more important. The quality and aesthetics of a car’s exterior significantly influence how a vehicle presents itself in the eyes of potential buyers. A striking grille makes a car stand out from the competition and is more likely to appeal to a specific customer group. Minimalist grilles, for example, are an attractive feature of modern city cars because of their elegance and simplicity. On the other hand, more expressive grilles with a more dynamic, aggressive flair are used on sports cars to attract the attention of hard-core driving enthusiasts.

Front grill – what materials can it be made of?

The choice of material for a car grill depends on several factors. Among these are: the technical parameters and aesthetic qualities to be characterised by the grill and the expected cost of production. What materials are typically used in the manufacture of car grilles?

Thermoplastic materials

Many manufacturers use thermoplastic materials to manufacture car grills. One material in this group that is used in the manufacture of car grilles is ABS or acrylonitrile-butadiene-styrene. This material is characterised by its rigidity and resistance to mechanical damage and high temperatures. The properties of components made from it are also influenced by the processing conditions. Components made by molding ABS at high temperatures gain better gloss and temperature resistance, while lower-temperature manufacturing processes ensure higher durability. Corrosion resistance and low production costs are also important factors in the context of car grills made from this material.

Composites

Composite materials are primarily used to manufacture grills for exclusive car models. Manufacturers are particularly keen on carbon fiber, which, apart from its elegant design, is also characterised by its low weight and high resistance to mechanical damage. This material is also often chosen by customers deciding to buy an elegant bespoke grill. However, the unique qualities of carbon fiber grills go hand in hand with a higher production cost than, for example, thermoplastic grills.

What are the functions of the grill in the car?

The grille in a car performs several different tasks. Some of these car users are not even aware of it. What are the most important functions a car grill performs?

Ensuring adequate airflow to the radiator

The primary role played by the car grill is to guarantee the correct airflow to the car’s cooling system. This is important because, during driving, the parts under the engine compartment lid heat up and a lack of external airflow could lead to overheating and subsequent failure. The use of a grill tailored to the needs of a specific vehicle model enables the vehicle to maintain the right temperature under the bonnet and assists the radiator in cooling the engine.

Protecting the radiator and engine from contamination

The car bonnet is a kind of barrier between the external environment and the engine compartment. Its purpose is to protect the radiator and engine from various types of debris, such as leaves, insects, or small stones that could get under the bonnet and damage the car.

Improving the aerodynamics of the car

Aerodynamics is of particular importance in vehicle design. As a result, it requires a great deal of care in the way the vehicle’s exterior components are constructed. The design and technical parameters of the car grill can, to some extent, influence how the air resistance acting on the car is shaped. Among other things, the shape and size of the openings in the grille, as well as its height and width, play an important role. However, it should be noted that at the lower speeds at which cars are driven, for example in the city, the impact of the grill on the aerodynamics of the vehicle is much less noticeable.

Shaping the aesthetics and unique character of the car

Whether it is the unique “kidney grille” of a BMW, the stylish horseshoe design of a Bugatti, or the distinctive triangular shape of an Alfa Romeo, there is no doubt that the grille’s function as a “business card” for a brand, and sometimes also as an identification mark for a specific model, is one of the most important tasks of a car’s grille. The grille with the manufacturer’s logo attached to it gives the car an identity and contributes significantly to its aesthetics. A beautifully crafted grille that has been well matched to the car’s design is one of the key aspects influencing how a model will be perceived by potential customers.

An example that perfectly illustrates the aesthetic importance of the grille and the extent to which drivers are attached to this element is the evolution that the Nissan Leaf underwent between the first and second generations. The first generation of the electric car did not have a grille – in purely functional terms, the grille was not needed on the battery-powered model, so the decision was taken to eliminate it. This move was met with a mixed reception among the brand’s customers. However, the voice of the proponents of traditional design was so strong that the grill has already been returned to its place in the second generation Leaf model, to the satisfaction of many Nissan fans.

The aesthetic function that car grills have played in combustion cars for years is difficult to overestimate. Brands with a rich history often choose to use this body element on electric cars as well. This allows aesthetic consistency to be maintained especially for models available in both electric and combustion versions. Manufacturers with a shorter history on the market are more likely to opt for the elimination of grilles from their vehicle designs, as exemplified by Tesla and some of its models that are devoid of the classic grill.

How does Endego’s front grill design process work?

Creating a front grillthat combines functionality and remarkable aesthetics is quite a challenge for designers and engineers. At Endego, we have unique know-how and extensive experience in the area of industrial design of Exterior category components. We have been successfully implementing technological projects in this area for more than a decade, working with leading companies in the automotive sector. What does the process of designing automotive fascias look like for us?

The initiating stage of the entire process is the Concept Studies phase. In this phase, we carry out several activities, such as

• establishing the customer’s needs and requirements,
• comparative analysis with existing competitive solutions on the market
• we select materials to achieve the expected properties of the designed front grill.

The information obtained in this phase is used in decision-making and the implementation of activities in subsequent phases of the project.

Once the Concept Studies phase is complete, we move on to the design phase, which includes the following:

• parametric CAD modeling,
• performing tolerance chain calculations,
• carrying out CAE analysis,
• verification of design feasibility,
• preparation of comprehensive documentation.

At this stage, our main objective is to design a component that will have the required technical parameters and aesthetics to match the design and character of the car.

Once the design phase is over, the prototyping phase begins. The work carried out within this is based on so-called prototyping loops, which consist of:

• creation of a 3D model,
• production of the prototype,
• assembly of the prototype,
• validation of the created model.

We repeat the prototyping cycles until one of the versions of the front grill prepared by us fully satisfies the customer and is accepted by him.

Comprehensive product development by us involves maximum involvement in every stage of the work: from the preparation of the initial concept to the start of series production. In this way, we increase the chances of the ongoing project being a complete success. Importantly, we provide our partners with professional advice throughout the duration of the cooperation, including, among other things, on-demand support.

Do you need the support of a team of engineers and designers with experience in automotive projects to help you develop a stylish front grill that perfectly complements the exterior of the car you are designing? Get in touch with us!