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Cost effective instrument panel design and development techniques were employed on the 1999 Audi TT sports vehicle, reducing the piece cost and enhancing performance. Technical solutions demonstrated include improved foam adhesion, eliminating the use of primer; thin wall injection molding technology, reducing the weight of the plastic retainer; heat aged performance improvement, reducing the cost of poor quality; as well as innovative development methods which reduce the total program costs. These development methods include the validation of a hidden air bag door design, which incorporates a thin wall retainer molding with integral plastic halo surround. The thinner wall helped Audi engineers reduce the weight of the part, adding to vehicle performance. Air bag system validation costs were also streamlined with the use of high frequency data acquisition in coordination with dynamic analysis simulations of the event.

Closed loop engineering methods are presented which demonstrate the design of an instrument panel retainer for optimal system performance characteristics such as NVH (noise, vibration, and harshness) and component integrity during crash. These methods incorporate finite element analysis techniques in concert with data acquisition of component and systems test to provide a closed loop analysis to test correlation of performance. Upon validation of the instrument panel systems model for a specific performance attribute, options to improve the system performance or reduce the cost may be reviewed analytically, replacing the historical “cut and test” method. Furthermore, the manufacturing process definition for the retainer is developed concurrent with the plastic part design. Manufacturing analysis methods are used to determine material flow, part cooling, part shrinkage, and ultimately, retainer fit and finish profile.