At the Outset
We needed to construct a full-scale replica of a hydrogen fuel cell engine measuring 1220 x 1153 x 834 mm.
The Challenge
Optimising a 3D design assembly file of size greater than 2GB containing over 1000 components for manufacturing presented significant technical obstacles.
Our Approach
We focused on assembly understanding, model optimisation and component categorization.
Our Process
Work began with engineering analysis and component sorting into categories (machining, 3D printing, fabrication, purchased items). We optimized design files for wall thickness and assembly feasibility, reducing development costs through strategic planning before manufacturing components in batches with assembly testing.
Our Work
Services included large file handling, 3D sculpting, design for manufacturing, 3D model optimization, and advanced analysis services.
The Result
The engine is displayed at Bosch's Bengaluru experience center and has spawned additional replicas used for corporate events, business development, and employee training on industry practices.