RIVIAN

DFM STANDARDS

AME-DFM-R7
CONTENTS

01 Foreword 05
1.1 Purpose
1.2 Development
1.3 Use of
1.4 Tolerances
1.5 Design for additive Manufacturing

02 Terms/Abbreviations 05
2.1 Definitions

03 Stampings 06
3.1 Draw and Form
3.2 Guidelines for Strengthening Beads
3.3 Flange Criteria
3.3.1 Windshield Flange length
3.4 Pierce Criteria
3.5 Trim Criteria
3.6 Weld Criteria
04 Closures 20
4.1 Doors
4.2 Fenders
4.3 Hood
4.4 Rear Quarters
4.5 Roof
4.6 Inner Wheel House/Sails

05 Roll Form and Castings 34

5.1 Roll Form
5.2 Castings

06 Hot Stamping and Extrusions 34

6.1 Hot Stamp
6.2 Extrusions

07 Joining and Hemming 35

7.1 Resistance Spot Welding
7.1.1 Minimum Metal Thickness
7.1.2 Design Guidelines Governing Metal Thickness
7.1.3 Electrode Usage and Flange Dimensions

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 7.1.4 Weld Pitch
7.1.5 Joint Strength
7.1.6 Electrode Clearance and Access Holes
7.1.6.1 Electrode Access Holes
7.1.6.2 Closed Section and Angled Shanks
7.1.6.3 Closed Section with Return Bend Shanks
7.2 Clinch
7.2.1 Joining Process
7.2.2 Cross Section Features
7.2.3 Typical Clinch Applications
7.2.4 Clinch Joint Compatibility
7.2.5 Flange Requirements
7.3 Self-Piercing Rivets
7.3.1 Joining Process
7.3.2 Cross Section Features
7.3.3 Typical SPR Applications
7.3.4 SPR Joint Compatibility
7.3.5 Flange Requirements
7.4 Flow Drill Screws
7.4.1 Joining Process
7.4.2 Cross Section Features
7.4.3 Typical FDS Applications
7.4.4 FDS Joint Compatibility
7.4.5 Flange Requirements
7.5 Laser Welding
7.5.1 Joining Process
7.5.2 Design Recommendations and Applications
7.5.3 Laser Joint Compatibility
7.5.4 Flange Requirements
7.6 GMAW (Arc Welding)
7.6.1 GMAW Process
7.6.2 Design Recommendations and Applications
7.6.3 Joint Compatibility
7.6.4 Joint Design Tolerance and Gap
7.6.5 Fillet Weld
7.6.6 Slot Weld
7.7 Adhesive (Dispensable)
7.7.1 Adhesive Joint Design Recommendations
7.7.2 Adhesive Bead Size Flanges with Design Gaps
7.7.3 Contacting Overlap (Flange Width)
7.7.4 Design Deliverables for Adhesive Definition
7.8 Fasteners (Body Attachment)
7.8.1 Projection Weld Nut/Stud
7.8.1.1 Weld Equipment Clearance
7.8.2 Drawn Arc Weld Stud
7.8.2.1 Studs in Aluminum
7.8.2.2 Studs in Steel

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 7.8.3 Clinch Nut/Stud
7.8.4 SPAC Nut/Stud
7.9 Robotic Hemming
7.9.1 Flange Development for Robotic Hemming

08 Plastic (Injection Molding) and CFRP 77

8.1 Molded Components
8.2 CFRP

09 GD&T PLP/SPC/KPC 78
9.1 GD&T
9.2 Minimum slip plane clearance
10 Paint and Surface Treatments 79
10.1 Surface Treatment
10.2 Topcoat
10.2.1 Fascia to Body Color Match
10.2.2 Fascia Radii
10.2.3 Electrostatic Painting

11 General Assembly Guidelines 80

11.1Process Framework
11.2 General Assembly Guidelines
11.3 Wire Harness attach Guidelines
11.4 Part Loading
11.4.1 Straight Load Clearance Chart
11.4.2 Articulated Load Clearance Chart
11.5 Retention Features
11.6 Hand Tooling Clearance
11.6.1 Socket Clearance
11.6.2 Tool Clearance Zones Securing Bolts
11.6.3 Tool Clearance Zones Securing Nuts

Appendix 93
A.1 References

Revision History 93

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 01 FOREWORD
1.1 Purpose
This document is meant as a tool for use in conjunction with Rivian APQP, Quality, Stamping, Molding,
Inspection Fixture, PPAP, and Assembly Tool Standards and Control Plans. For Design Engineering
Products that the manufacturing process can and will obtain and produce a consistent product (part or
assembly).

1.2 Development
This document was developed using best practices of the North American Automotive Industry along
with reference (basis), from Assembly Tool, Injection Mold, Stamping, PPAP and FMEA standards set
forth by the North American Automotive Industry in conjunction with the Rivian Engineering department.
The development of this DFM standard/guideline, is to design products that are easily manufactured.
The DFM will allow potential problems to be addressed at the design stage, whereas the manufacturing
process is addressed along with the costs associated with the feasibility of the design of the product.
Addressing the DFM in the product design phase allows costs to be contained at the earliest and most
cost-effective opportunity.

1.3 Use of
Depending on the type of manufacturing process there are set guidelines for DFM practices. This
standard/guideline is to help precisely define the tolerances, rules and common manufacturing checks
related to DFM.

1.4 Tolerances
The geometric tolerance given to product is one the main contributors to the cost (note all features shall
have a tolerance assigned), the lower the tolerance the higher the cost. When designing a feature or
component, the loosest tolerance that will allow the component to obtain the desired function of the
part shall be used. Creative manufacturing and engineering methods with higher tolerances, producing
functioning components shall be the Rivian objective.

1.5 Design for additive Manufacturing

Additive manufacturing, is a common term for describing, technologies used for building/assembling
materials usually by layer by layer, as in hot roll, cold roll, hot stampings, plastic, etc. 3D CAD designing
for additive manufacturing allows the designer to optimize the design to save material, cycle time,
assembly process, machining needed, etc. Strong DFM practices can be considered to be subtractive
manufacturing, helping to control costs right up front of the actual manufacturing process.

02 Terms/Abbreviations
2.1 Definitions
AM – Additive Manufacturing (assembling materials together)
DFM – Design for Manufacturability
DFMEA – Design Failure Mode and Effects Analysis - DFMEA is the application of the Failure Mode and
Effects Analysis method specifically to product design. It is an analytical method performed cross-
functionally and used in engineering to document and explore the ways that a product design might fail
in real world use.

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FEA – Finite Element Analysis
FTA – Functioning Tolerancing and Annotation
Home Line – Final production facility location chosen for production of such product.
KPC- Key Product Characteristic
MSA – Measurement Systems Analysis of an approved GRR (see the Rivian Automotive Check Fixture
Standards AME-IF-R1)
PCP – Process Control Plan, is a documented description for controlling processes for part production,
it shall address key parameters of the process along with all KPC’s and is used to minimize any variation
that may occur to the process or product. It is a living document that needs to be updated for EC or
process changes that may occur over the entire program, right into the service life of the product.
PFMEA – Process Failure Mode and Effects Analysis, is a technique to identify potential failure modes of
the process and is a major contributor to the Process Control Plan. PFMEA will assist in issue
containment during production. The PFMEA shall be updated with any EC, and must contain the latest
part level for submission, and is to be considered a living document.
PFC – Process Flow Chart is the flow of materials through the process. (Incoming materials inspections
right up to fully approved PPAP, and eventual final delivery of products)
SOP – Start of Production
SPC – Statistical Product Control
SQE – Supplier Quality Engineer (Rivian personnel)
Tool – Tool will be used for this document as meant to be the tool that produces the product this is
being submitted for PPAP. Tool could be a mold, die or assembly equipment.

03 Stampings
This section shall define the criteria Rivian uses for designing components that can be successfully
stamped and later assembled.

3.1 Draw and Form

 Optimum draw depth is 115mm or less.
 Backdraft designed as a last resort only.

 Parts shall be designed with open end draws where possible, using parallel breaks on the end
of the part with no closed corners.

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  Material stretch shall be within the safe region of forming limit diagram and have fatigue
requirements satisfied.
 Steel 25% or less stretch is considered safe.
 Aluminum 12% or less for preliminary analysis.
 All severe or local shape changes shall be softened where permissible.

 Draw walls shall be the same depth when possible to eliminate twist.

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  Draw walls shall be open a minimum of 6 degrees.

 Shown below are draw sections radius recommendations based on the depth of draw, note
this is a rough guide only and can vary based on the substrate.

B - Base Radius of C - Top Radius of

A - Depth of Part
Part Part
0 -13mm 6mm 5mm
13 - 26mm 10mm 6mm
26 - 39mm 13mm 7mm
Over 39mm 19mm 9mm

 Plan view Radii shall be greater than 1/3 of the pocket depth.

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  Avoid parts that are drawn using pre-bends or rotators. Parts with characteristics needing a
pre-bend or rotator, shall be ran in a double action press or parts will need to be split.

 Follow guidelines to prevent skid lines on class “A” panels:

 Forces shall be balanced on either side of a feature line.
 Forming features shall be at least 100mm from the part edge or other features.
 Forming features shall be a minimum of 30 degrees open as shown.

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3.2 Guidelines for Strengthening Beads

A - Width of Bead B - Inner Radii

7.0 mm 3T
10.0mm 3T
13.0mm 3T
16.0mm 4T
19.0mm 5T
25.0mm 5T

B - Inner C - Radii at D-
A - Width
Draw bottom of Draw
of bead
Radii draw depth
25.0mm 2T 3T 9.0mm

 Add strengthening beads and metal offsets in areas where metal has less than 3% stretch – to
improve dynamic performance and increase dimensional capability.

3.3 Flange Criteria

 Design flanges, so that they can be directly formed to their finished shape in one operation if
feasibly possible.
 Flange length shall be a minimum of 2X of metal thickness (gage) beyond the tangent. (Note
longer is better)

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  Return flanges in die position shall be eliminated, unless feasibly unable too.

HIGH COST DIE ACCEPTABLE

 Return flanges in die position when feasibly needed.

 All channel shapes shall be twice as wide as deep, when feasible, (rule of paint application).

 Flanges shall be designed without closed corners, when feasible. (Considerations for sealing
requirements shall be addressed)

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  Non-HSLA steel, all flanges shall be designed for 3 degrees open in the final position.

 Recommended HSLA Steels and Aluminum use table:

Approximate spring
Yield Strength
back allowance
0 - 30 KSI 3 degrees
40 KSI 4 degrees
50 KSI 5 degrees
60 KSI & Alum 6 degrees

 Considerations for flange length - compression and stretch conditions.

 Notches shall be required for stretch.
 Gainers shall be required for compression.
 Ideally to prevent unwanted conditions - keep flange length reasonable.

 Flanges shall be designed without die lock conditions. (Impossible without a fill slide)

 Flanges shall avoid unbalanced thrust in the die position, when feasible.

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  Avoid flanged cutouts, when feasible.

 Flanged round
Mean Flange
holes: Punch Size mm Flanged Holes Size
Height +/- 1.0
10.0 15.0 2.5
11.0 17.0 3.0
13.0 20.5 3.5
16.0 24.5 4.0
19.0 28.5 4.5
22.0 31.5 4.5
25.0 34.0 4.5
28.0 37.0 4.5
32.0 41.0 4.5

 Flanged slot openings: Mean Flange

Punch Size mm Flanged slot L x W
Height +/- 1.0
9.0 x 18.0 11.5 x 23.0 2.5
11.0 x 22.0 14.5 x 28.0 3.0
13.0 x 26.0 17.5 x 33.5 3.5
16.0 x 26.0 21.5 x 40.5 4.0
20.0 x 40.0 26.5 x 49.5 4.5

 Preferred surface containing the extruded holes shall be perpendicular to the piercing
direction.

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  Adjacent surfaces to flanges that are used for holding, shall be 2X the width of the flange.

DIM. "A" TO BE 2X "B"

WHENEVER POSSIBLE.

3.3.1 Windshield Flange Length

 Standard flange length for Windshield attach (the flat) from tangent to edge is 25.0mm, in special
cases a minimum of 22mm may be allowed.

3.4 Pierce Criteria

 When feasible all hole and openings shall be the last stamping operation along with PLP’s,
when possible some trim action may be combined in this step.
 Piercing all holes and slots in the last operation at the same time shall be the objective,
avoidance of process drivers is recommended.
 Maintain hole piercing in the same plane as trim operations, whenever possible. (Maximum
piercing shall be limited at 10 degrees)

 Common hole and slots sizes shall be used whenever feasible.

 Standard punch sizes for round holes:
Standard punch sizes for round holes
3.0 4.8 7.5 12.0 19.0 32.0
3.2 5.0 8.0 12.5 20.0 38.0
3.4 5.3 8.5 13.0 21.0 44.0
3.6 5.6 9.0 14.0 22.0

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 3.8 6.0 9.5 15.0 24.0
4.0 6.3 10.0 16.0 25.0
4.3 6.7 10.5 17.0 26.0
4.5 7.1 11.0 18.0 28.0

 Best practice for length to width ratio on rectangular or oblong holes, is 2:1, note for locating
features common practice is 1.5 to 2.0:1.

Standard Punch Size mm

20.0 x
4.0 x 8.0 6.0 x 12.0 11.0 x 22.0
40.0
4.5 x 9.0 9.0 x 18.0 13.0 x 26.0
4.8 x 9.6 10.0 x 20.0 14.0 x 28.0
5.0 x 10.0 21.5 x 40.5 15.0 x 30.0
5.6 x 11.2 26.5 x 49.5 16.0 x 32.0

 All noncircular holes shall have a minimum 1.5mm corner radius.

 Flat distance from a hole to the edge of a part shall be 3mm or greater. (Y)
 Flat distance from an edge of a hole to a radius/tangent shall be 5mm minimum. (Z)

 Distances between holes shall be sufficient to allow use of standard piercing equipment,
25mm is the preferred minimum distance, with 10mm being the maximum minimum allowed
before special piercing practices shall be instituted.

DISTANCE BETWEEN HOLES

DIMENSION "X"
25mm PREFERRED MIN.
X
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  Holes/slots that require two operations to pierce, shall be avoided, unless infeasibly possible.
(EX: holes on two surfaces such as a door inner latch attaching holes)
 Avoid holes in surfaces more than 20 degrees apart in their angle, it is preferred any one
pierce angle to be 10 degrees from trim surface if feasible.

 Holes shall be placed with a proper distance from flange walls to use standard piercing
equipment, avoiding holes being too close to flange walls.

X = 10mm minimum preferred

X 7mm acceptable

 Surfaces containing countersunk or self-clinching pierce nut shall be perpendicular to the

piercing/ram (press) direction.

Press direction

 When using a flanged hole, verification use of a rosebud or nail-punched hole is feasible to
use. (Preferred method)

 2-way and 4-way locating holes and slots shall be parallel to body grid, using offset formations
when necessary, unless feasibly impossible.

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  2-way and 4-way locators, shall be space as far apart as feasibly possible.
 Vertical panels as shown, shall have the locators place above the center of gravity on fixtures
built in car position.

 Master locators, shall be coordinated between, sub assembly parts, (components) and body
construction key characteristics.
 Tightly toleranced holes and hole patterns, shall be in the same plane as master locators, and
pierced in the same last operation.

3.5 Trim Criteria

 Trim shall be designed so that the entire part can be trimmed in press direction, unless
feasibly unable.
 Trim angle shall be 15 degrees or less.

 Distances from the radius tangent to the trim shall be 10mm or greater when the angle is less
than 135 degrees.

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  Trim walls at the end of panels shall be at minimum of 10 degrees open for shear in die
position.

B B
10 MIN
A
A
PLAN VIEW END VIEW
A
A
10 MIN
B
B

 When Trimming across an angular surface, the relationship between the die plan view and trim
corners shall be 60 degrees minimum.

60
OR MORE

AVOID LESS THAN

60 DEG TRIM CORNERS
 Trim relief shall be 2X metal thickness at flange ends.

TRIM RELIEF AT FLANGES 2X METAL

THICKNESS

PLAN VIEW
PLAN VIEW PLAN VIEW

HIGH COST
ACCEPTABL PREFERRE
DIE CONDITION

 Trim notches shall be 5X metal thickness, and a minimum of 5 Degrees open.

TRIM NOTCHES MIN. 5 OPEN EACH

SIDE
PLAN
PLAN VIEW VIEW 4X MTL.
GAGE
HIGH COST
ACCEPTABLE
CONDITION AND
DIFFICULT TO SHED
SCRAP

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3.6 Weld Criteria

 Sufficient flange width must be maintained for gun clearance to the wall angle.

FLANGES TOO SHORT 14mm MIN.

FLAT

WELD GUN
WALL INTERFERENCE TIPS
WITH WELD
HIGH COST ACCEPTABLE
CONDITION
 Spot weld flange length minimum width is 14mm + radius for traditional weld tips.
 Laser welding requires 6mm of flat for joining.
 Weld arrestor flanges shall be provided in areas where weld flash will be objectionable. (Door
belt flanges, and any area adjacent to a Class A surface)

WELD GUN
PROTECTOR

 Self-Piercing nuts to be considered in lieu of welds nuts, when and where possible.
 Considerations for surface offsets in areas between welds to isolate areas from a dimensional
control standpoint.

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  Consideration for adding weld castellation’s when the vehicle mass is near or exceeding
targets. Weld castellation’s add cost and complexity to tooling but is a reasonable cost mass
reduction strategy.

X X X X X X X
X X X X X X X

04 DFM Closures
4.1 Doors

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4.2 Fenders

CURVATURE IN THE SIDE VIEW TO BE 0 OR

MINIMIZED TO REDUCE FLANGING PROBLEMS

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4.3 Hood

10.0 R MIN TYP SHOULD MATCH RADIUS

WITH BSO

10.0 R MIN TYP SHOULD MATCH

#40 SWEEP MAX IN PV
RADIUS WITH BSO
AT GLASS FOR HEM

15.0R AT 90
#12 SWEEP MIN 10.0R AT 100
60 5.0R AT 110
60.0 MIN

#22 SWEEP MAX AT REAR

25.0 MIN FROM END
OF FEATURE LINE
FOR HEM 60.0

100.0 MIN

#10 SWEEP MIN

FEATURE LINE
6.0 DEEP MAX.

STRAIGHT BREAK
FRONT TO REAR

40.0R WITH A 40X45 HEM IN RAD

ELIMINATE BEAVER TAIL

FLANGE AND/OR
DRAW
DIRECTION

30.0 MIN WITH A 6.0 MAX HEM

MUST BE 3 DEG OPEN EACH SIDE IN 107 DEG MAX

FLANGE DIE POSITION 107 DEG MAX

SECT A-A

MUST BE 10 DEG OPEN

NO DOWN STANDING OFFSET FLANGES TO DRAW DIRECTION
NO CLAM SHELL HOODS

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4.4 Rear Quarters

ANGLE BETWEEN MUST BE OPEN

IN DRAW DIE

6.0R MIN.
6 DEG MIN OPEN

15 DEG MIN OPEN

115.0 MAX.
13.0 MAX CONSTANT DEPTH OFFSET
TAPERING TO 0 AT TOP AND BOTTOM 60.0

SEC A-A
15.0R MIN.
2.5R MIN. 30 DEG MAX OR PROVIDE 25.0 MAX
AN OFFSET SURFACE TO
REDUCE THE TRANSITION 2.5R MIN.
ELIMINATE LOCK
FACE
RADIUS MUST BE THREE TIMES SEC E-E
DEPTH AT CORNER THIS IS TYPICAL
AROUND WINDOW OPENINGS

PROVIDE A COMMON ANGLE

ALONG C'LID AND B'LIGHT FOR
SINGLE CAM OPERATION

CONSTANT RADIUS IN WHEEL OPENING

REDUCES LOWS AT 10 AND 2 O'CLOCK
10.0 MIN OFFSET
TAPERING TO O AT TOP
AND BOTTOM

FEATURE LINES SHOULD BE NO CLOSER

THAN 100.0 MIN TO THE BOTTOM AND SEC D-D
BELTINE BREAKS. FEATURE LINES
SHOULD NOT BE MORE THAN 6.0 DEEP
MAX BY 18.0 WIDE MIN. AT EDGE OF
PANEL

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4.5 Roofs

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4.6 Inner Wheel House

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 05 Roll Form and Castings
5.1 Roll Form
 Constant section is the primary requirement for a roll form part.
 If swept, sweep to be constant as well for forming with end rolls.
 Holes can be pierced in line prior to roll entry. (<+/- 1.50)
 Post processed holes required tool access from two sides. (Gage holes, for example)

Roll Former

5.2 Castings
 Minimum draft is 1o.
 Maintain thickness that allows for metal flow and fill in-the-mold.
 Avoid thick areas that will result in a hot spots and sinks.
 Parting line to be designed in non-critical areas.
 Pull angle to be provided prior to product design.
 Provide allowance for post-machining including part set up for machining.

06 Hot Stamping and Extrusions

6.1 Hot Stamp
 Liberal trim tolerance shall be expected, due to difficulty of trimming boron steel in-tools.
 Critical trim areas and locating holes to be lasered trim. Can be trimmed and pierced in tool at
considerable cost.
 PHS still requires similar forming/stamping criteria as cold stamp parts.

Heating and Forming for Hot Stamping

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6.2 Extrusions
 Parts require uniform wall thickness.
 Corners require a minimum 0.50 - 1.0mm radius.
 Internal and external walls shall have the same thickness.
 Rounded transitions shall be used.

Aluminum Extrusion

07 Joining/Hemming
Joint Classifications
 Category J1: Any joint whose failure results in structure collapse or a catastrophe failing. These
joints should be reinforced with additional joints and recategorized into a J2 category.
 Category J2: Joints which require compliance with Federal Motor Vehicle Safety Standards.
Failure of such joint has a direct impact on performance or functionality of the vehicle, also
termed as “Critical Joint” or “Delta Joint”.
 Category J3: Joints whose individual failure can be acceptable, but multiple joint failure can
impact performance or functionality of the vehicle.
 Category J4: Joints that are manufacturing joints to aid in the assembly process. And failure of
such joint has no impact on vehicle performance or functionality. An optimized design should
utilize Category J2 and J3 for the purpose of a J4 joint.

Note* selection of a joining method is dependent on the joining stack up. For a full list of available
joining methods refer to the joining summary follow the link shown below,

https://rivian.sharepoint.com/:x:/r/Manufacturing/Standards/DFM%20Standards/Joining%20Summary.x
lsx?d=w61a6f1c5cc6944cc9196756dc3d57cb5&csf=1&e=8eFkSj

7.1 Resistance Spot Welding

7.1.1 Minimum Metal Thickness
 Minimum nominal thickness for standard components and processing practices is a function
of the material coating.

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 Minimum Nominal Metal Thicknesses
Metal coating Minimum Nominal Thickness
None (Bare) 0.65mm
Electro Galvanized 0.70mm
Hot Dipped Galvanized 0.75mm
Galvanneal 0.70mm

 The maximum allowable stack up thickness is 6mm for Steel and 9mm for aluminum.
 Individual sheet thickness shall be a maximum of 3mm.
 4T welds shall be avoided.
 Deviations to the above criteria shown will require welding trials and Manufacturing/Plant buyoff.

7.1.2 Design Guidelines Governing Metal Thickness

 Governing metal thickness (GMT) is used throughout this standard and is for establishing
design and manufacturing parameters such as weld flange length, weld pitch, electrode
Gauge ratio Limitations outlines the generic gauge ratio limitations applicable to double and
triple panel welding of sheet steels. Ratios are based on the minimum yield strength and
positions of the steels in the stack up. When one of the outside sheets in a stack up is a
Group 4 steel, the more stringent ratio limitations shown below in Example 2 shall be used.
 selection, etc. GMT for double or triple panel welding is defined as:
 The thickness of the thinnest sheet in a double panel stack up.
 The thickness of the second thinnest sheet in a triple panel stack up of unequal
thickness.
 The thickness of one of the equal sheets in a triple sheet stack up having at least two
sheets of equal thickness.

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 Gauge ratio Limitations

RelationshipGMT Example

X Y Z X Y Z

X Y Z X Y Z

X Y Z X Y Z

X Y Z X Y Z

X Y Z X Y Z

X Y Z X Y Z

X Y Z X Y Z

X Y Z X Y Z

Deviations to the ratio requirements shown shall require welding trials and Manufacturing/Plant
Engineering signoff.

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7.1.3 Electrode Usage and Flange Dimensions
Shown are standard electrodes and associated minimum values for flange overlap and flange width for
double and triple panel welding. A design radius of 3 mm shall be assumed for all flange widths. Note
operations may have additional requirements for flange widths. Use of weld through adhesive or sealer
shall require an additional 1mm of flange shown in the table below. Reductions to these standard values
requires testing and Manufacturing/Plant Engineering signoff

Standard Electrodes and Minimum Values for Flange Overlap and Width for Double and Triple Panel
Welding

 The use of 13/5 mm electrodes to achieve shorter flanges is only applicable for steel welding and
requires testing and Manufacturing/Plant Engineering buyoff.
 For triple panel combinations, the 20/8 mm electrode may be replaced by a 16mm electrode if the
thinnest sheet is 0.8 mm or less. Based on the testing specific application, Manufacturing
Engineering will determine whether a 6mm or 8mm face is required.

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 Aluminum Panel Welding

 The use of electrodes smaller than a 19mm or 20mm Outer Diameter to achieve shorter flanges for
aluminum welding requires testing and Manufacturing/Plant Engineering signoff.

7.1.4 Weld Pitch

The weld pitch is the distance between the centers of two adjacent spot welds. Listed are minimum
weld pitch values, that shall be maintained to reduce the risk of a shunt effect.

 Note the shown values are can be reviewed with manufacturing, an example would be
intrusion beam welding on doors when the thickest part is 1.5-2.0mm minimum spacing would
be 25mm.

7.1.5 Joint Strength

 Typical and minimum joint strength of resistance spot welds are shown in the tables below.
Joining strength is a function of GMT of the stack up. 3T stacks shall be analyzed as two
separate 2T joints where the GMT at each interface is used to determine the minimum and
typical strength requirements at the respective interface.

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 Minimum Nominal Design Spot Weld Spacing Steel and Aluminum

Thickest part Spacing for 2 metal- Spacing for 3-metal

contacting electrode thickness welding thickness welding
(mm) (mm) (mm)

1.00 20.00 27.00

1.13 22.00 29.00
1.25 25.00 33.00
1.38 28.00 37.00
1.50 30.00 40.00
1.75 32.00 43.00
2.00 35.00 47.00
2.25 38.00 51.00
2.50 42.00 56.00
2.75 46.00 61.00
3.00 50.00 67.00

 Lap shear strength for Resistance Spot Weld is dependent on both the thickness of the
governing material, t (mm), and the ultimate tensile strength of the governing material, UTS
(MPa). Relationships between material thickness and strength to the required minimum
and typical lap shear strengths are given in the table below. Test specimens shall be
fabricated and tested per AWS D8.9, Section 11.6.1

Material Min (kN) Typical (kN)

UTS < 800 : −0.7 + 9

(−6.36 -7 × 2
+ 6.58E -4 × +1.674)
Steel UTS UTS

1.5 UTS > 800 : −1.7 + 13

1000(4 UTS )-1

Aluminum −0.9 + 2.5 −0.6 + 2.5

Min strength equation for spot welds is adopted from AWS D8.1.

 Cross Tension strength for Resistance Spot Weld is dependent on the thickness of the
governing material, t (mm). Relationships between material thickness and the required
minimum and typical cross tension strengths are given in table below. Test specimens shall
be fabricated and tested per AWS D8.9.

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 Material Min (kN) Typical (kN)

UTS < 800 : −5 + 9

2.2
Steel 1.25
UTS > 800 : 0.3 + 3.6

Aluminum −1.8 + 2.7 −1.1 + 2.8

Min strength equation for spot welds is adopted from AWS D8.1.

7.1.6 Electrode Clearance and Access Holes

7.1.6.1 Electrode Access Holes
 When resistance spot welding requires access through an in-line access hole, the access hole
shall provide adequate clearance for the electrode.
 Requirements for size of the access hole is determined by the electrode size and the distance
of the access hole from the surface to be welded.
 Shown are clearance and access hole dimensions for a 16 x 20 electrode cap.

Minimum In-Line Access hole Diameters for electrodes

7.1.6.2 Closed Sections with Angled Shanks

 When resistance and spot welding require access in a closed section, a minimum clearance is
required between the flange welded and surface opposite of the welded flange.
 Required clearance is influenced by the size of the electrode cap and the angle of the electrode
shank.

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 Minimum Clearance Distance for a Closed Section

7.1.6.3 Closed Sections with Return Bend Shanks

 When resistance spot welding through an access opening with a return bend shank, the access
opening shall provide adequate clearance for the electrode cap and shank as shown.

Closed Section with a Return Bend Shank

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7.2 Clinch
7.2.1 Joining Process
 Strippers clamp metals between a punch and die guard. A punch then shears two edges and draws
the metals into the die. The punch continues traveling and squeezes then expands to lock in the
metals. Strippers hold the joined metal in place to allow the punch to be retracted.

7.2.2 Cross-Section Features

 Technical descriptions used for clinch joints.

CT = Cap Thickness
BD = Button Diameter
LL = Interlock Left
LR = Interlock Right
NL = Neck Left
NR = Neck Right
PD = Punch Diameter (nominal joint mm)
T1 = Thickness punch side metal
T2 = Thickness die side metal

7.2.3 Typical Clinch Applications

 Clinch can be used on a variety of automotive assemblies where lower tensile strengths are
required, a few applications to name are:
 Hoods
 Sunroofs
 Decklid/Tailgate
 Roof Bows
 Package Trays
 Attaching Sound Deadening Material

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7.2.4 Clinch Joint Compatibility
 The table below covers most of automotive body combinations. Green cells mean that the joining
stack up is feasible and the joint can be utilized without consulting Manufacturing Engineering, a
yellow cell means that the joint may be possible, but testing is required before applying it, red
means that the stack up combination is impossible with clinch technology.

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7.2.5 Flange Requirements
 Most common body applications use 12mm, 14mm, and 16mm clinch dies, the table below gives a
generic idea about minimum flange and pitch of joints based on the overall stack up, however the
final decision about selection of a die is based on physical testing. For a better design practice,
flanges shall be designed based on the bigger die diameter. (For example: total stack up of 2mm
shall use a flange of 16mm diameter)

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 Round Point Die skB Die
preferred series
Point diameter [mm]
5 6 8 10 12 6 8 10

Die diameter outside [mm] 10 12 14 16 20 12 14 16

Overall sheet thickness [mm] t1 + t2 1.0 - 2.5 1.0 - 3.0 1.6 - 6.0 1.75-7 4.5 - 11.0 0.4 - 2.5 0.6 - 5.0 1.0 - 6.0
edge distance [mm] ≥a 5 6 7 8 10 7.5 8 8.5
Distance to start of border radius
5 6 7 8 10 7.5 8 8.5
[mm] ≥b
Pitch [mm] ≥ e* 10 12 14 16 20 14 16 18
Min. die height [mm] 6 6 6 6 6 14 14 14

clearance [mm] ≥d 20 20 20 25 30 30 30 35

7.3 Self-Piercing Rivets

7.3.1 Joining Process
 Self-piercing riveting (SPR) is a process whereby all materials in a stack up are joined using a tubular
rivet. A punch drives the rivet through the materials and a die on the other side forces the bottom
of the rivet to expand forming a mechanical bond. Pre-clamping of the surrounding material helps
in controlling material flow.

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7.3.2 Cross-Section Features

 T1 (mm) – is the material thickness of the bottom layer.

 T2 (mm) – is the material thickness of the middle layer.
 T3 (mm) – is the material thickness of the top layer.
 tmin (mm) – is the thickness location in the bottom layer of an SPR joint where the material is thinnest.
 Y (mm) – is the perpendicular measurement between the head of the rivet and the surface of the
top layer, for a countersunk rivet. For a headed rivet, it is the distance between the underside of
the head and the top sheet of material. Positions of the rivet head above datum surfaces are
positive (+) and below the datum surface negative (-).
 SPR Interlock – is the horizontal distance between the tangential point of the leg side to the bottom
layer material and the tip of the rivet leg of same side. LL is the left-side interlock and LR is the right-
side interlock. For symmetry LL should be equal to LR.

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  D (mm) – Head Diameter of the Rivet.

7.3.3 Typical SPR Applications

 SPR joint is the most popular joining method for mixed material joining specially where aluminum
and steel comes together and there is two-sided access. For aluminum to aluminum joints, SPR joint
is preferred when higher fatigue strength is required, or joint is supposed to displace under crash
load.

7.3.4 SPR Joint Compatibility

 The table shown below covers most automotive body combinations. A green cell means that the
joining stack up is feasible and joint can be utilized without consulting Manufacturing Engineering.
A yellow cell means that the joint may be possible, but testing is required before applying it, with
red meaning that the stack up combination is impossible with SPR technology.

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7.3.5 Flange Requirements
 Most popular rivets in automotive applications are 3mm (shank diameter) and 5mm (shank
diameter) rivets, minimum flange requirements and pitch (distance between two rivets) is based
on the type of the rivet used.

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 Rivet
Minimum Flat required Minimum Pitch
Diameter
3.0 mm 16mm 25mm
5.0 mm 21.8mm 25mm

*with the use of special dies for a 3mm rivet, the minimum flange can be brought down to 14mm which
requires testing and buyoff from Manufacturing Engineering.

 Stack up with any sheet less than 1mm thick uses 3mm rivet.
 2T stack up with 3mm total thickness, 2T stack up with 4mm total thickness uses 5mm rivet.
 Anything between the two criteria’s shown above requires trials to decide the type of rivet used.

 All panels shall have a minimum 3mm clearance from the SPR gun components, the lower die frame
requires a minimum 7mm clearance for the gun to move downward after disengaging the joint to
move out.

7.4 Flow Drill Screws

7.4.1 Joining Process
 The flow drill screw joining process is a screw joint between two or more sheets of metal. A
clearance hole or pilot hole may or may not be required depending on material combination. The
sheet metal is heated by applying downward force on the flow drill screw with a high rotational
speed and force. As the metal is heated sufficiently, the flow drill screw penetrates the material
and forms an extrusion, which is used for a chip-less forming of the thread. The flow drill screw
tightens the components with the preset torque.

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7.4.2 Cross-Section Features

 l (mm): Nominal screw length

 lg (mm): Usable thread length of screw (lg should be greater than b)
 d1 (mm): Nominal thread diameter
 d2 (mm): Washer diameter
 k (mm): Head height
 s (mm): Washer thickness
 hU (mm): Head undercut height
 t1 (mm) – Thickness of clamped part 1
 t2 (mm) – Thickness of installation part
 dD (mm) – Clearance hole diameter (if req’d)
 dV (mm) – Pilot hole diameter (if req’d)
 b (mm) – Stack up thread length

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7.4.3 Typical FDS Applications
 Flow Drill Screwing is a single sided joining method used to permanently join body sheets
together where protruding screw head and sharp nail on other side are not a concern from
stacking and interference perspective.
 Commonly available Screw sizes are: M4, M5 and M6 (Repair Screw)
 Commonly available Screw lengths are: 17mm, 21mm, 25mm and 30mm
 Commonly available Head styles are: Hex, Torx, internal Torx, etc.

Bottom Layer Recommended Thread

Bottom Layer Material Gage Diameter
0.50 – 0.75 M3 – M5
Steel 0.75 – 1.25 M4 – M6
1.25 – 2.00 M5 – M8
0.50 – 1.00 M3 – M5
Aluminum 1.00 – 2.50 M4 – M6
2.50 – 3.80 M5 – M8
Source: DVS/EFB 3440-4

 To communize, External Torx M4 x 21 Screws will be preferred for joint development which
covers most gages unless a different screw is necessary.

7.4.4 FDS Joint Compatibility

 The table below covers most automotive body combinations. Feasibility is recommended based
on a M4 x 21 screw. Green cells mean that the joining stack up is feasible and the joint can be
utilized without consulting Manufacturing Engineering, a yellow cell means that the joint may be
possible, but testing is required before applying it, red means that the stack up combination is
impossible with FDS technology, “hole” means a clearance hole required on the top sheet(s),

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7.4.5 Flange Requirements
 The table shown below table shows the minimum flange requirements and pitch (distance
between two screws) for the flow drill screw. For certain stack up combinations FDS does not
require a pilot/clearance hole(s) on the top sheet but for some applications it will be necessary to
have hole(s) on the top sheet.

Flange flat Screw center to Minimum Screw

overlap ( c) trim edge (a) Pitch center-center
2T 22.8mm 11mm 21mm
3T 24.8mm 12.4mm 22mm

 The chart shown below shows hole size requirements where (AFF 4.0 = M4, AFF 5.0 = M5 and AFF
6.0 = M6)

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Flow Drill Screw exerts a considerable amount of force during installation processes, the stiffness of
assembly must be validated before designing the joint to avoid manufacturing issues.

7.5 Laser Welding

7.5.1 Joining Process
 Laser Welding is a non-contact process which requires access to the weld zone from only one
side of the part being welded. The laser weld is formed as an intense laser light rapidly heats the
material - typically calculated in milliseconds. The most common Laser welding used in
automotive manufacturing is keyhole mode welding.

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 Laser Weld
(keyhole)
Overlap
Joint Edge Joint

Seam Stitch Butt Joint

Seam
Weld Weld Weld

Linear Stitch
Stitch Weld

Staple

Circle

 Different configurations of laser welded joints can be produced depending on the application.
Shielding gas and/or filler wire can be added to the process where necessary to improve joint
strength, eliminate hot cracking and for brazing purposes.

7.5.2 Design Recommendations and Applications

There are three major reasons for selection of Laser welded joints over conventional resistance welding,
 High Speed Joining
 High strength requirement
 Short flange requirement
The advantages shown above come at the expanse of:
 High capital investments
 High equipment maintenance
 Process sensitivity
Rules to consider with laser welding:
 Only similar materials should be considered for welding with Laser technology.

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  Laser welds shall not be considered for Class A surfaces or other visible surfaces of the vehicle.
 Zinc coated steel requires a design gap of 0.1 - 0.3mm for zinc gases to escape during the welding
process. This gap can be achieved by several different methods like:
 Adding groves in the stamping process
 Using laser ablation to clean the surface
 With clamping devices etc.
 Edge welding is preferred in zinc coated steel
 Laser welds shall be at least 10mm away from any adhesive or sealer in the body.
 Hot cracking is common in aluminum 6XXX series. Use of 6XXX series requires filler wire adding
complexity to manufacturing.
 For full penetration welds, parts below the bottom welded sheet shall be at least 5mm away to
avoid beam reflection issues.

7.5.3 Laser Joint Compatibility

 Most of the same family of materials can be welded by laser technology, some grade combinations
may require shielding gas and/or filler wire to overcome porosity, hot cracking issues. Certain gage
ratios have proven incompatible in the past, which shall be avoided in the design.

Top Layer
Overlap
0.5mm 1mm 1.5mm 2mm 2.5mm 3mm
0.5mm
Bottom Layer

1mm
1.5mm
2mm
2.5mm
3mm

Top Layer
Edge
0.5mm 1mm 1.5mm 2mm 2.5mm 3mm
0.5mm
Bottom Layer

1mm
1.5mm
2mm
2.5mm
3mm

7.5.4 Flange Requirements

 Minimum flange is typically dependent on the clamping requirement.

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  The table shown below shows the minimum distance between the trim edge and weld bead. This
distance can be more in cases of high strength steel and certain aluminum grades. Minimum weld
stitch shall be 25mm in length and only 80% of total length shall be used in CAE modeling ignoring
10% from both ends.

 Successful weld trials on the full assembly are required to finalize weld flanges. As a starting point,
the following minimum overall flange flat shall be used for laser joints:
 Remote Laser Welding Aluminum (10mm)
 Remote Laser Welding Steel (8mm)
 Laser Seam Stepper (10mm)
 Laser Edge welding with Seam Stepper (10mm)

7.6 GMAW (Arc Welding)

7.6.1 GMAW Process
 Gas metal arc welding (GMAW) is a welding process in which an electric arc forms between a
consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s),
causing them to melt and join.
 GMAW can also be referred to as MIG (Metal Inert Gas) or MAG (Metal Active Gas) which also
encompasses the same process. Another popular arc welding method called CMT (Cold Metal
Transfer) can also be covered in the same guideline.
 Following are the types of joints possible with Arc Welding:
 Butt Joints
o Square-groove welds
o V-groove welds
o Bevel-groove welds
o U-groove welds
o J-groove Welds
o Flare-V-groove Welds

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 o Flare-Bevel Groove Welds
 T-Joints
o Fillet Welds
 Lap Joints
o Fillet Welds
o Plug Welds
o Slot Welds
o Arc spot welds

7.6.2 Design Recommendations and Applications

 Three thickness joint design is not recommended.
 GMAW closer than 25mm to surfaces or edges coated with sealer or adhesives is not
recommended.
 The Minimum specified weld length shall be 13mm or greater.
 Excessively large weld size, which results from more than one pass of weld, is not recommended.
 All joints shall be designed in such a way that there is adequate joint repeatability for welding.
 Basic weld position is recommended that all welding joints be positioned for welding in either the
flat or horizontal position whenever possible.
 The horizontal or vertical plane of the flat and horizontal joint may vary up to a maximum of 10
degrees.
 Free machining steels are not allowed when the welding process is GMAW.
 Both parts and tooling should be designed to enable proper access of the selected weld gun to the
weld joint, thus, allowing the weld to be performed in the optimum position. Fillet welds should be
designed to allow fitting of the torch without any interference from other parts, stamping features,
or tooling. They shall also be designed to obtain the electrode stick out distance recommended by

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 the electrode manufacturer’s technical data sheet. In most instances it is sufficient to design the
joint to fit the torch nozzle at 45° from the weld joint root.
 Intermittent welds that are properly sequenced can help keep joints closed by reducing the heat
input which reduces distortion. However, intermittent welds also introduce weld starts/stops,
both of which are stress risers. Like continuous welds, weld start/stops of intermittent welds
should be placed away from high stress areas.

7.6.3 Joint Compatibility

 For steel joints, both the steel thickness and thickness combinations specified by product design
are limited by the capability of the arc welding process. The recommended steel thickness limits
and maximum combinations ration for the GMAW process are shown.

Maximum
Minimum Maximum
Combination
Thickness* Thickness
Ratio
3.0mm 9.0mm 0.1

 For Lap Joints, it is recommended that the thinner steel be the top steel.
 Use of sheet thickness less than 2.0mm may be specified in AHSS but may require corrosion
protection.
 Certain chemical elements may have detrimental effects on the weldability of steel, guidelines
shown can be used as a reference for a designer to choose steels.

Sulfur (S) Phosphorous (P) Boron (B)

Content Content Content
≤ 0.05% ≤ 0.06% ≤ 0.005%

 The CMT process can accommodate thinner materials than shown above. Trials shall be
conducted to verify compatibility of stack ups.

7.6.4 Joint Design Tolerance and Gap

 The design gap tolerance (G) of 0.0 – 0.5mm is allowed for all weld joints, with an edge trim
tolerance (E) of +/- 0.5mm is required where the edge is part of the weld joint.
 Variation of edge location causes variation in alignment of the electrode wire with the weld joint.
Misalignment of the electrode may cause poor weld shapes, improper fusions, and burn-
throughs. For controlling this variable, the trim tolerance at the weld joint shall be held to +/-
0.5mm and the electrode shall maintain a root joint alignment tolerance of +/- 0.5mm.

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  The best-case scenario would be the smallest gap possible and the gap shall not exceed the
smallest sheet of metal thickness or 1.5mm whichever is the smallest including the tolerance stack
up.
7.6.5 Fillet Weld
 Sufficient overlap of (12mm) to account for the variation of the trim edge for both the top and
bottom sheets as well as variation in locating the sheets, shall be accounted for.

7.6.6 Slot Weld

 Slot welds shall only apply to lap joints, slot welds shall be single sided or double-sided slot
welds.

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 Minimum Slot Size and Spacing for Fillet Welds
Minimum
Minimum Slot Length (L) X Minimum
Slot Width Y Minimum mm
mm mm
(W) mm
2.0≤T<3.1, L = 25.4
5xT L (0.5 x L) + W
3.1≤T<4.6, L = 31.8

7.7 Adhesive (Dispensable)

Adhesive bonding (also referred to as gluing or glue bonding) describes a wafer bonding technique with
applying an intermediate layer to connect substrates of diverse types of materials. In body applications
the use of adhesive is mainly between metal to metal to attain various attributes like crash toughness,
body stiffness, corrosion protection, etc.
 BIW Engineering defines bead diameter, bead pattern and location on relevant CAD drawings or
files.
 Selection of adhesive shall be made with agreement of Advanced Manufacturing Engineering by
verifying dispensing attributes and life of the adhesive at different states.
 For purposes of CAD/CAE, path length and bond length are to be equal.
 For manufacturing and inspection purposes, the two terms are used to differentiate between the
adhesive material as dispensed and as compressed states.
 Adequate locating devices may be required for proper adhesive placement.
 The adhesive supplier’s recommendations shall be followed as the first guide.
 All conditions shall be verified during the design phase by engineering, manufacturing, and the
adhesive supplier.

 Adhesive Path Length - Path Length refers to the length of adhesive applied to the surface of the
product prior to being assembled. Minimum path length shall be 100mm.

 Adhesive Bond Length - Bond Length is the compressed adhesive length of the adhesive joint
that will be inspected as one group and shall be agreed upon with both Body Design and
Manufacturing Engineering Departments to achieve targeted functional benefits of the bond.

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  Adhesive Bond Width - Bond Width is the width of the compressed adhesive between mating
flanges. The target for bond width is 10mm, although minimum required bond width can vary
depending on the application.

 Adhesive Excluded Length - Excluded Length is the length of flange that is not subject to
adhesive specification. Excluded lengths include:
 Cutouts
 Holes
 Narrow flange widths
 Large gaps/Notches

When contact overlap reduces to ≤10mm, the entire reduced

length plus 10mm from both sides can be excluded from the CAE model and can
be skipped.

For any type of hole, notch, or cut-out the entire

length plus 10mm from both sides can be excluded
from the CAE model and can be skipped.

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 When a design feature such as a stiffening bead or slip plane introduces a gap
more than nominal gap for adhesive, the entire bond length shall be excluded
from the CAE model.

 Adhesive Effective Length - Effective path length refers to the section of length that is subject to
the conditions of the specification. The path length minus excluded lengths equals the effective
length. This specification requires that 100% of PEL, demonstrates the presence of adhesive as
inspected on the part that received the adhesive prior to part joining and 80% of BEL demonstrate
the presence of adhesive and shall be inspected during testing tear down after reaching the
compressed state.

Effective Bond Length BL – EL = BEL

Effective Path Length PL – EL = PEL

 Skip Length - Skip is defined as the skip of adhesive in a continuous bead. Skip and shall not be
more than 5mm in length.

7.7.1 Adhesive Joint Design Recommendations

 Adhesive Scalloped Flanges - Scallops shall not be used on flanges in which adhesive will be
dispensed.

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  Adhesive Castellated Flanges - Castellated flanges are flanges with periodic design gaps, often
used to encourage the free flow of E-coat. If material is dispensed along the entire length of the
flange including the castellated sections, the dispensed material can wash out in the paint shop.

 Adhesive Stich Beads - Stich beads are a series of short beads that are used instead of a
continuous bead, usually on instances of a castellation flanges to limit washout or to avoid
squeeze out from spots under high joining pressure.

7.7.2 Adhesive Bead Size Flanges with Design Gaps

When dispensed material is intended to bridge a design gap between two substrates, the dispensed bead
shall contact the surface of both substrates when the bead is closed out. If the bead does not contact
both surfaces when closed out it will most likely wash out in pre-treatment or E-coat tanks. For dispensing
adhesive beads intended to bridge design gaps see the sizing chart.

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 Design Bead
Gap Diameter
(mm) (mm)
0.0 3.0
1.0 3.0
2.0 3.0
3.0 5.0
4.0 6.0
5.0 8.0

7.7.3 Contacting Overlap (Flange Width)

Contacting overlap refers to the common flange width of the mated surfaces and serves as the stress
transfer location of the joint. It is recommended that adhesively-bonded parts have contacting a overlap
≥15 mm as measured in CAD and compressed adhesive coverage of 10mm. Use of adhesive on parts
providing less than the required contacting overlap requires the approval of the relevant Body and
Manufacturing Engineering departments. See the table shown below for compressed bond width
coverage based on flange width reductions below 15 mm.

Contacting Flange Minimum Compressed

Overlap Width
(mm) (mm)
≥15 7
12.0 – 14.9 7
11.0 – 11.9 6
10.0 – 10.9 5
< 10.0 Not allowed

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7.7.4 Design Deliverables for Adhesive Definition
The following specification for each adhesive bead shall be defined by the body design team in CAD:
 Adhesive Product
 Bead Diameter
 Bead Length
 Bead Pattern
 Minimum bond length (coverage area)
 Skip length if any

7.8 Fasteners (Body Attachment)

This section covers body fasteners, which get attached to the body/panel prior to its final assembly at a
later process in End of Line or General assembly. The table shown below is the preferred nut/stud
joining method in the body shop.

Assembly
Nut/Stud Process level fastener type
Manual Part level Projection Weld (Hex with flange)
Part level Projection Weld (Hex with flange)
Nut
Automated Assembly
level Drawn arc weld
Steel Panel
Manual Part level Projection Weld
Part level Drawn arc weld
Stud
Automated Assembly
level Drawn arc weld
Manual Part level Clinch nut
Nut
Automated Part level SPAC nut
Aluminum Manual Part level Clinch Stud
Panel Part level SPAC stud
Stud
Automated Assembly
level Drawn arc weld

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7.8.1 Projection Weld Nut/Stud

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 Fastener Size Relative to Sheet Metal Thickness

Fastener Size Minimum/Maximum Sheet Metal Thickness mm

Round/Hexagon Round/Hexagon Round/Hexagon
Square Nut
Thread Nut/Bolt Nut/Bolt Nut/Bolt
Size Three Banana
Four Continuous Ring Three Circular
Shaped
Projections Projection Projections
Projections
M6 0.5 - 1.5 0.75 - 2.5 0.5 - 1.5 0.5 - 0.8
M8 0.75 - 2.5 0.9 - 2.0 0.75 - 2.5 0.8 - 2.0
M10 0.75 - 2.6 1.25 - 3.0 0.75 - 2.5 1.25 - 2.0
M12 1.5 - 3.0 1.25 - 3.0 1.0 - 3.0 1.5 - 2.2
M14 1.5 - 3.0 1.5 - 3.0 1.5 - 2.4
NA
M16 1.5 - 3.0 1.5 - 3.0 NA

Hole Sizes for Base Sheet Metal

Hole Diameter for Flanged and Piloted Weld Nuts

and Weld Bolts
Hole Diameter
Thread Hole Diameter for Weld Nuts
for Weld Bolts
Size mm
mm
Flanged Nut Piloted Nut
+0.5/-0.0mm
+0.5/-0.0mm +0.15/-0.0mm
M6 7.50 9.00 6.30
M8 9.50 13.00 8.30
M10 11.40 15.00 10.30
M12 13.90 17.00 12.30
M14 15.90 19.00 NA
M16 18.00 NA NA

7.8.2.1 Weld Equipment Clearance

 Product design shall supply adequate clearance for electrodes of production welding
equipment.
 Consideration for clearance of the electrode in the zones above and below the intended weld
fastener.
 Upper electrode is applied on the same side as the fastener.

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  Lower electrode is applied on the opposite side of the fastener.

*Option 3 is un-available for Weld Bolts.

Electrode Clearance Requirements

Fastener Type A> B> <C D> H< I>
Square Weld Nuts 30 60 60 180 50 140
Flanged Weld Nuts 38 76 60 200 50 140
140 +
Weld Bolts 30 60 60 NA 50
L
L is nominal length of the bolt (> = greater than and < = less than)

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 Square Weld Nuts
Weld
Thread
Nuts and
Size E < 16 E > 16 E < 16 E > 16
Bolts

F> G> F> F> G> G>

M6 37 19 35 45 18 23
M8 40 20 40 45 20 23
M10 43 22 45 45 13 23
M12 46 23 50 50 25 25
M14 49 25 50 50 25 25
M16 52 26 60 60 30 30
Weld Equipment Clearances F and G (mm)

7.8.2 Drawn Arc Weld Stud

7.8.2.1 Studs in Aluminum

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  The minimum possible wall thickness of aluminum components to be stud welded with a 5mm
diameter studs is 1.0 mm, without cracks appearing on the component back side. Selection of a
Drawn Arc Stud on Aluminum shall be done based on the supplier’s recommendation and
preliminary testing on coupons to develop and validate joining parameters.
 The table below shows minimum clearances required for placement of Drawn Arc Studs, a full
clearance study shall be conducted for verification.

Min. Flat Min. Distance

Min. Flat Min. Distance Min. Distance
required on between
Fastener Type required on between center between center to
Fastener center to trim
Other side to wall center of fastener
side edge
T - Stud 25 N/A 45 15.5 25.5
T5/T6
32.5 N/A 45 19.25 29.8
Threaded
M6 w/Flange 35 N/A 45 20.5 34
M8 w/Flange 35 N/A 45 20.5 35.3
M8 Ground
35 N/A 45 20.5 35.3
w/Nut
M10 Ground
40 N/A 45 23 39.7
w/Nut

7.8.2.2 Studs in Steel

 Most steels can have a drawn arc stud welded on it, with the thinnest base material at 0.65mm thick,
material thinner than 0.65mm requires trials and development at a supplier to confirm feasibility.
 30mm of flat area is required to weld a DAS stud.
 Minimum distance between the center of a stud to the wall is 40mm.

7.8.3 Clinch Nut/Stud

Selection of a clinch fastener is highly dependent on the selected product. Refer to the product drawing
for recommended hole sizes. The table below shows details about generic clinch fastener required
clearances, a full verification shall be performed with the suppliers selected tooling.

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 Min. Distance
Min. Flat Min. Flat Min. Distance Min. Distance
between center
Stud Type required on required on between between center
to center of
Fastener side Other side center to wall to trim edge
fastener
M5/M6 22 22 16.0 9 13
M8 25 25 20.0 11 17
M10 30 30 24.0 13 21
M12 30 30 26.0 14 22

Min. Distance
Min. Flat Min. Flat Min. Distance Min. Distance
between center
Nut Type required on required on between between center
to center of
Fastener side Other side center to wall to trim edge
fastener
M5/M6 20 20 18.0 10 15

M8 24 24 20.5 11.25 17.5

M10 26 26

M12 28 28

7.8.4 SPAC Nut/Stud

 The table below shows basic guidelines of allocating SPAC nuts, full validation data shall be
submitted to the supplier for tooling verification.

Min. Distance
Min. Flat Min. Flat Min. Distance Min. Distance
Fastener between center
required on required on between between center
Type to center of
Fastener side Other side center to wall to trim edge
fastener
M6 12 27 9.9 12.5 36
M8 15 30 11.5 15.3 36
M10 19 33 13.8 19.5 36
M12 26 37 17.4 25.85 N/A
M14 28 45 18.4 27.75 N/A
M16 30 48 19.5 29.75 N/A

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7.9 Robotic Hemming

7.9.1 Flange Development for Robotic Hemming

Flanging Process developed on a punch die. (pre-hemming), inner flange die radius:
 Aluminum 1.5mm
 Steel 0.5mm

Section of Flange Die Stamped

Roll Hemming typically has a 0.0 <> 0.2mm roll-in, caused by different movement patterns of the process.

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 Roller Hemming Process 3-Step Roll Forming Process

3-Step Roll Forming Process

Roll in of a Hem

 Roll hemming typical has a 0.0 – 0.2mm roll-in for Aluminum, likely caused by the different
movement patterns of the process.
 Corners and panels transition from different flange lengths as required.

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 08 Plastic (Injection Molding) and CFRP
8.1 Molded Components
 Mold flow analysis – Is an indispensable program for the design of plastic injection molded
components, ROI of running a simulation on our components is undeniable for added
performance, molded quality, and appearance.
 Draft angles minimum of 0.5 degree (small depth parts) and optimum minimum of 3 degrees
ungrained and protection for grained surfaces at 7 degrees minimum draft.
 Design no sharp corners for molding, radii shall be in the range of 0.9 – 1.2 times the thickness of
the part.
 Plastic wall thickness as uniform as possible to avoid warpage and uneven shrinkage, when wall
thickness variation is unavoidable transition shall be gradual. (step thickness transition shall be
avoided)

Example of Uniform Wall Thickness

 When using bosses or ribs, wall thickness shall be 60% of main surface thickness where they
attach surface to control sink.
 Consideration for surface finish needs to be confirmed Smooth, Etched, Painted, or Grained at
the design stage.

8.2 CFRP
CFRP – Carbon Fiber Reinforced Plastics used to reduce weight, combine parts, or for replacing hard to
stamp metal components.
 Considerations for CFRP are much like Injection molded parts, as to draft and radii, tolerancing is
on the high/large side. Z-profiles and double bent surfaces shall be avoided.
 Ribs for strengthening shall not exceed main body part thickness, with an optimum rib thickness
at 0.6 times part thickness to control sink.
 Gates shall be considered by the part design; proper placing should include considerations for fill
and final appearance. (B side gates or edge gates)
 Undercuts should be avoided and designed suitable/allowable split lines shall be considered on
all injection molded components.
 Over molding or 2 shot molding is a common consideration for hiding “rat holes”.

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 09 GD&T PLP/SPC/KPC
9.1 GD&T
Key principles:
• Requires Design and Manufacturing working together to keep tolerance accumulation less
significant as more components are assembled.
• Uses ASME Y14.5-2009 standard 3, 2, 1 principles for locating.
• Consistent datum sizes - 25 x 25mm A datums, even mm locating sizes for B and C datums.
• Orientation of datum schemes square to Car position - making adjustment easy and clearly
defining moves needed for correcting tolerances/build issues.
• Standardize handling and assembly operations resulting in manufacturing education for
design.
• Flatness applied to a reasonable overall form tolerance, preventing abrupt surface variations
near assembled mating surfaces.
• Specify common unilateral tolerances, as a rule unless otherwise. (+/- 0.50mm example)
• Slip plane clearance part to part is 4.0mm as a standard.
• Standard hole and slot sizes (6, 8, 10mm, etc.) for all holes and slots – reduces tool costs
• Avoid small radii, holes, and slots – robust design - controls tooling repairs and helps
eliminate scrap.
• Coordinated Locating Schemes
• Requires datum schemes along with proper placement of KPC/SPC points for controlling
attachment of components for ease and accuracy of assemblies
• Coordinated locating schemes simplify design and assembly for unambiguous
processes used for:
• Solid mounting of component level parts.
• Assembly tools (work holding) and inspection fixtures.
• Top level vehicle body pins down to the first component manufactured.
• Practical DFM practices can be a driver for:
 Holding tightly toleranced products in check right at the design stage, keeping
tolerances aligned with manufacturing capabilities and controlling costs.
 Component datums designed as to be assembled only one way that consistently
maintain orientation

Examples of Common Locators

9.2 Minimum slip plane clearance

 Minimum clearance for a slip plane part to part is 4mm.

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 10 Paint and Surface Treatments
10.1 Surface Treatment
 All box sections shall incorporate openings that permit fluids to enter and fill the cavity within 15
seconds of immersion.
 All box sections shall be capable of draining all fluid contents within 30 seconds of exiting the
liquid bath when the vehicle is no more than 5 degrees from level.
 Placement of entry and exit holes should avoid the “A” surface of the exterior of the vehicle.

Surface Treatment Tank

 Door drains can be designed by creating slots in the inner panel at the bottom of the door inner
panel which can later be sealed after electrocoat with Hem Sealer. The number of these holes is
determined by the volume of the door and the drain time required.
 In the electrocoat oven, the body structure shall be capable of reaching a metal temperature of
365F in 7 minutes maximum and holding that temperature for 35 minutes.
 Method for Determining Drain Hole Size and Location:

The liquid volume flow is calculated using the following formula: = 2

where:

=Volume flow (cubic meters/sec)

=Area of aperture – Flow Outlet (square meters)
= Discharge Coefficient =
for sharp edged apertures = 0.62, for rounded edge apertures =0.97
= Velocity coefficient. For water = 0.97, The paint will be just below this
number, about 0.92.

10.2 Topcoat
10.2.1 Fascia to Body Color Match
 Fascia to body mating surfaces shall meet at an angle of at least 15o from vertical in body position
when viewed from the side of the vehicle.
 Fascia’s shall not mate with the fender either as a completely vertical or horizontal fit.
(Completely vertical or horizontal mating creates a condition where the fascia will appear either
light or dark in relation to the body)
 Components such as the fender to fascia will be matched numerically (paint code), but when
joined they will not match, due to the very slight change in approach angle of the two surfaces
when joined together.

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  By intersecting the two parts (fascia and fenders) at an angle, the difference is significantly
reduced.

10.2.2 Fascia Radii

 All fillet radii of fascia components such as molded in grilles, cut lines, part mating edges, and
openings shall have a 2mm minimum radius. (This minimizes the “edge pull” effect of paint
applied to the surface of the fascia)
 A coating applied to a plastic surface or any surface with low surface energy will tend to “thin out”
or pull away from any sharp edges. Applying a 2mm radius reduces this effect on the painted part
and enhances color match and durability associated with film thickness.

10.2.3 Electrostatic painting

 Body features that consist of a ditch, groove, or recessed pockets shall follow the dimensional
rule of depth ratio. Features width shall be a minimum of 2 times wider than they are deep, due to
the Faraday Cage effect – charged particles of paint will be repelled from entering the groove
or ditch of the width is less than 2 times the depth, paint will not be applied to such surface per
the faraday effect.
 Edges of doors, body panels, roof edges, closeout panels, and flanges that are painted shall not
have a sharp point, sharp points in the electrostatic paint process attract paint, resulting in sags,
runs, and excessively thick paint on the edges causing rework.

11 General Assembly Guidelines

11.1 Process Framework
High-level build strategy exists, to be refined when data is developed.
 Frequency: Weekly
 Process: ME evaluates the latest Delmia math release and separates the car into sub-assembly’s
(partitions) by latest build sequence assumptions.
 The assumptions are built from evaluating the vehicle as well as the plant constraints, land
marks, and legacy build flow (Brownfield Facility).
 The ME will build an IA structure that captures the subassembly and within that
subassembly, the viewer will click on the plus sign to explode out or view the parts that
were consumed to build the sub-assembly.
 Eventually, each part number from the MBOM will be linked to a Job Element Sheet (JES)
that contains the technical data for each sub-set of parts (torques, KPC’s, Mandatory
Sequence if required, Poka Yokes).
 A series of JES’s are assembled to build the Standard Operations Sheet (SOS or
standardized work) which is the current best practice or documented build sequence.
The SOS is a living document which can be CIP’d when efficiencies are gained (controlled
at the operator level). The JES can only be changed as an output of a formal Engineering
Change process communicated in a Change Control Board (CCB).
 Example: Instrument Panel separated from the vehicle and assembled per forecasted
station structure
 Outcome:
 Identify design interferences, crash conditions, and no-build conditions.
 Example: current master cylinder reservoir is covered by the plenum leaf screen (no fill
head access)

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  Developing build sequence, standardized work, and capturing Key Product Characteristics
(KPC) like FMVSS torque specs., ergonomic conditions.
 Data is used to construct the Virtual Builds, MCB builds, and VP builds. Issues are
collected, discussed and vetted, and agreed upon issues are assigned to each Director for
resolution for architectural.

High level Tools that feed the process:

 EBOM: Engineering Bill of Materials
 Reflect sub-assemblies, assemblies, and partitions
 Example: fastener type, count, and location
 Owner: Engineering
 MBOM: Manufacturing Bill of Materials
 Reflect optionality post-paint
 Optionality to be included in data for comprehensive virtual build.
 Owner: ME but fed from EBOM
 GD&T: Geometric Dimensioning and Tolerancing
 Including locating schemes
 Owner: Engineering
 DTS: Design Technical Specifications
 Owner: Engineering
 VTS: Vehicle Technical Specifications
 Owner: Engineering
 Variation Analysis
 Owner: Engineering
 DFMEA: Design Failure Mode Effects Analysis
 Owner: Engineering
 PFMEA: Process Failure Mode Effects Analysis
 Owner: ME but fed from DFMEA

11.2 General Assembly Guidelines

 Simplify the design and reduce the number of parts
 Standardize and use common parts and materials
 Design for ease of assembly
 Common torque as necessary
 Common fasteners
 Poka-Yoke (Error Proofing)
 No blind installs
 Ensure adequate access & unrestricted vision
 One-way connectors (prevent bent pins and incorrect orientation)
 4-way and 2-way location scheme
 Ensure parts self-align & self-locate
 Preference for 4-way to be located on outer panels/pillars for operator visibility (IP install)
 Prevent tolerance stack-ups
 Slip joints (cover overlaps and gaps)
 Straight forward option variables
 Incorporate subassemblies where applicable (POA examples: Console, Headliner, Brake
Line Bundle)
 Ensure parts are easily handled from bulk

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  Limit Finesse (Example: extruded rubber parts and interior trim)
 Design for parts orientation and handling
 Eliminate possibility of installing opposite of design intent (“flip flop” brackets)
 Minimize reorientation (assemble in Z axis) & secondary operations during assembly
 Part size considerations (too big, too small, too heavy)
 Design within process capabilities and avoid unneeded surface finish requirements (soft touch
paint)
 Design for base part to locate other components (emphasize “top-down” assemblies)
 Design for efficient joining and fastening
 Design modular products (strive to eliminate adjustments)
 Make parts symmetrical or obviously asymmetrical.
11.3 Wire Harness Guidelines
 Requirements for wire harness attachment.
 Spacing shall not exceed 225mm for all electrical clips.
 Electrical clips shall be orientated within 30 degrees of attachment direction.
 Writing on wire shall face the operator in the install position for easy definition. (Down if
attached under the vehicle or up if attached above the vehicle, facing the operator for 90
degrees install)

11.4 Part Loading

11.4.1 Straight Load Clearance Chart

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 Load Obstruction
Rigid
Soft / Class A Critical
(Non-
Compressible Surface Component
Show)
Soft / Compressible
(Loose Wiring, Carpet, Silencer, > 0mm 2mm 10mm
Hoses)
Hand Load
Somewhat Flexible A-Side: A-Side:
(Fascia, Interior Trim, Wheel A-Side: 10mm A-Side: 10mm
10mm 15mm
Liner)
B-Side: B-Side:
Hand Load B-Side: > 0mm B-Side: 10mm
Load

10mm 10mm
Rigid / Non-
Compressible (Brackets, > 0mm 10mm 15mm
Modules, Pumps)
Hand Load

Assisted Load 15mm 25mm

Assist Arm Load

Notes:
A side – Surface visible to the customer
B side – Surface not visible to the customer

11.4.2 Articulated Load Clearance Chart

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 Load Obstruction
Soft / Class A Critical
Rigid
Compressible Surface Component
Soft / Compressible Total:
(Loose Wiring, Carpet, Total: > 0mm Total: > 25mm
>10mm
Silencer, Hoses)
Hand Load Min: > 0mm Min: >2mm Min: > 10mm

Somewhat Flexible Total: Total:

(Fascia, Interior Trim, Wheel Total: 25mm Total: 25mm
25mm 30mm
Load

Liner)
Hand Load Min: 10mm Min: 10mm Min: 15mm Min: 10mm
Rigid / Non- Total:
Compressible (Brackets, Total: > 0mm Total: 35mm
25mm
Modules, Pumps)
Hand Load Min: > 0mm Min: 10mm Min: 15mm
Total: 35mm Total: 55mm
Assisted Load
Min: 15mm Min: 25mm

11.5 Retention Features

Retention Features, allows a part to be positioned in the vehicle so that an operator has both hands free
for tools and fasteners Use:
 A retention feature is required when installing a part to an overhead surface
 A retention feature is required when installing a part to a vertical surface

Examples of Retention Feature:

Hook
Up-turned hook prevents a component from rotating and falling out.

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 Self-Retaining J-Nut

Stud

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 Doghouse with Clip:
Utilization of an integrated doghouse with a clip. The clip shall not be integrated into the component to
avoid damage to component if the component must be removed.

Hand start nut Raise part thru keyhole Slide part laterally Torque nut

Teardrop Retention Feature

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 Clip
In case of a harness and hose application an Omega style clip is preferred over a C clip

11.6 Hand Tooling Clearance

11.6.1 Socket Clearance
 Safety torque for a Class A surface
 For a Safety torque around a class A surface, a safety sleeve shall be required, to ensure
that there is a minimum of 4mm clearance to the socket with the safety sleeve as
shown below.

• Non-Safety torque
 For Non-Safety torques, a safety sleeve is not mandatory. Ensure that there is a
minimum of 2 mm clearance to the socket.

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11.6.2 Tool Clearance Zones Securing bolts:
 Approach position
 Gun Start of the bolt: place the fastener in the tooling (gun) and position 5mm away
from the location to be secured.
 Hand start of the bolt: show fastener with 3 mm of thread engagement, position tooling
(gun) 2mm above the top of the started fastener.

 Final position
 Position tooling (gun) over the fastener as if it were fully torqued down.

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  Tooling clearance zone
 Place the tooling (gun) in the approached and secured positions, confirm 2mm clearance
to surrounding components.

 Socket Clearance zone

 Ensure that there is a minimum of 2mm clearance to the socket with a safety sleeve

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11.6.3 Tool Clearance Zones Securing nuts:
 Approach position
 Gun Start of the nut: place the fastener in the tooling (gun) and position 5mm away from
the location to be secured.
 Hand start of the nut: show the fastener with 3 mm of thread engagement, position
tooling (gun) 2mm above the top of the started fastener.

 Final position
 Position tooling (gun) over the fastener as if it were fully torqued down.

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  Tooling clearance zone
 Place the tooling (gun) in the approached and secured positions, confirm 2mm
clearance to surrounding components.

 Socket clearance zone

 Confirm 2mm clearance to the socket with a safety sleeve.

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APPENDIX

References

DFM Criteria for BIW Sheet Metal Stampings Rev1 - Author AME Rob Walus

ADDITIONAL STANDARDS USED FOR THIS PUBLICATION

TYPE OF STANDARD IDENTIFICATION # REV LVL AUTHOR
Design Dimensional Standard AME-DD-R2 R2 AME (BS)
Inspection Fixture Standard AME-IF-R2 R2 AME (BS)
Stamping Die Standard AME-SD-R2 R2 AME (BS/RW)
PPAP Standard AME-PPAP-R1 R1 AME (BS/RW)
Supplier submission Procedure (PSW) AME-PSW-R1 R1 AME (BS/RW)
Material standards AME
Special Machine Standards AME-SM-R1 R1 AME (BS/BC)
Injection Mold Standards AME
Weld Standards AME-ATW-R1 R1 AME (BS/BC)
Assembly Tool Mechanical AME-ATMBCB-R1 R1 AME (BS/BC)
Build/Component BOM
Assembly Tool Electrical Standard AME-ATE-R1 R1 AME (BS/BC)
Assembly Tool Welding AME-ATW-R1 R1 AME (BS/BC)

REVISION HISTORY

REVISION DATE CHANGES AUTHOR

01 2/28/2018 ORIGINAL VERSION AME (BS, BC, RW)
02 3/21/2018 Revision 2 added sections AME (BS)
03 5/31/2018 Font/Logo Update AME (SS)
04 9/1/2018 Added chart on attaching, added GA req. AME (BS, MM, JP)
05 10/4/2018 Joining techniques edited AME (MM, BS)
06 10/19/2018 GA requirements updated AME (SV, BS)
Added Drain Hole info to 10.1 added min slip
07 2/11/2019 AME (BS, SS)
plane clearance GD&T 9.2

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