Case study · Automotive prototype
Carbon-fiber body panels for EV startup
Project · Automotive
Prototype carbon-fiber body panels for an electric vehicle startup.
A European EV startup needed a prototype set of body panels — hood, fenders, doors, and tailgate — in a single piece each, autoclave-cured carbon with class-A surface finish. Tight timeline: 14 weeks from design freeze to finished painted parts.
14wk
From design freeze to finished parts
Deliverables
- Design for manufacturing Joint review with client's design team
- Tooling plug & mold 5-axis machined tooling, autoclave layup mold
- Carbon parts (5 panels) Single-piece, autoclave cured
- Class-A paint & finish OEM-spec paint, finished & crated
CAD / CAM Engineering
DFM review and toolpath generation — caught three manufacturability issues before tooling investment.
About this serviceCaught three issues before tooling.
Our DFM review identified undercuts and radii issues in the original design. We worked with the client's design team to update the geometry before cutting any tooling — saving weeks of rework and protecting the timeline.
Process
5-axis CNC tooling
Process
Robotic composite layup
"
Brzoglas's DFM review saved us weeks. The parts were beautiful, on time, and the client walked the showroom floor with confidence.— Engineering Manager, EV startup
Working on a prototype?
DFM review is part of every quote — let's talk about your timeline.