Automotive Prototyping
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Automotive Prototyping

WayKen are focusing on automotive prototyping as a complete service which has allowed us to expand our knowledge and experience in this area. No matter from proof of concept design to mechanical component engineering test, or from exterior lighting prototypes to interior component prototypes, we are able to support at all levels.

We are experienced in automotive prototyping, and enjoy working with all types of technologies that will quickly make your design a reality. We are looking forward to your better experiences, and with WayKen, you will find which process best meets your needs and fits into your product definition.


Rapid Prototyping Driving Automotive Innovation

Prototyping Accelerates Automotive Development Steps

The automotive industry is a complex and huge industry, faced with market pressures it requires frequent design iterations and new design development. However, the automotive design and development cycle is a long process, so fast and efficient prototyping is a must-have bridge for it. Automotive prototype represents an important step in the validation process between the initial product design and final production run.

In fact, automotive prototyping not only plays a vital role during the design verification process, but also ensures that parts are manufactured with the best suitable material, and evaluates the manufacturing process.

Automotive prototypes are integral parts of the entire automotive engineering process that allow engineers to figure out how to make new automotive products appeal to consumers, to communicate ideas to stakeholders and project teams more quickly and efficiently, and to prove the value of a design to potential investors and customers.

In actuality, automotive prototype manufacturing always runs through the entire stage of the automotive design and development cycle, including the proof of concept, the visualizations of CAD digital model, the structure and performance verification, function and engineering test, and even for manufacturing and production process validation.

Automotive Concept Prototype and CAD Digital Model

During the concept design and 3D CAD modeling phase, automotive designers realize ideas to real objects by creating scale prototypes in the form of clay modeling. It can provide them deliberated basis in the stage of concept design. Later reverse engineering techniques will be used for scanning the model to get the CAD models and to optimal the design.

This back and forth conversation between design and automotive prototype creates an iterative process where each tool reveals new opportunities and problems to explore and further refine, and helps designers to better understand user experience. This works both externally - presenting to clients and stakeholders - and internally - in collaborating more deeply with your team, or rallying them to support a new idea.

The Structure and Function Verification for Automotive

Once a concept design has been validated, engineering design stage requires a more refined prototype to determine the usability of the product and to smooth any design challenges.

Automotive engineers sometimes refer to this as the “mule stage.” During this stage, engineers will create a series of automotive functional prototypes, and place the prototype products in the existing automobiles. According to the development of different models and the use of the mule, the prototype is usually used for form fit check of the component space and the initial performance data collection of the automobile.

This strategy allows them to see how the automotive prototype will fit in the vehicle and interact with the other parts, and help evaluate design, materials, strength, tolerances, assembly, working mechanisms, and manufacturability.

Engineering Testing and Pre-production Verification

Before an automotive part goes into production, engineers will create low-volume engineering test prototypes and pre-production components that simulate the final product, and quickly iterate their designs according to actual testing and feedback to meet the required performance, verification, testing, certification and quality requirements.

Automotive prototype is vital for safety testing. The prototype vehicles loaded with the test part are placed through different scenarios and subjected to extreme conditions to identify any problems that could hamper the use of the product or cause serious safety concerns to consumers.

Meanwhile, creating low-volume production components for new automotive product pilot runs allow engineers to spot possible production problems as well as determine the most cost-effective manufacturing processes.

Wayken’s Automotive Prototyping Technology
At Every Point In Your Process

With more than 20 years of engineering and prototyping expertise, WayKen thrives in technically challenging projects for automotive prototype engineering. We do strive to be your best full service product development partner in the automotive industry. We specialize in a variety of automotive prototyping developments and rapid manufacturing technology, providing CNC machining, 3D printing, vacuum casting, rapid aluminum tooling, low volume injection molding, and sheet metal processing, which maintain a competitive edge with innovative service and highly skilled workforce. We’ll work together – and with you – throughout every step of the automotive design and development process.

From full interior mock-up which include dashboards, consoles, door panels and pillars to exterior components such as bumper, grilles, headlights and taillights lighting prototypes, our team relies on its advanced machining process portfolio, and blending these with surface finishing operations, traditional hand skills, and in-depth know-how to support at all levels for the auto industry.

Our biggest asset is our customer base which has grown rapidly through customer’s word-of-mouth around the world. We are proud and honored to provide comprehensive prototype manufacturing solutions for some of the world’s leading automotive manufacturers and tier one suppliers, such as BMW, Bentley, Volkswagen, Audi and Skoda. Our goal is to exceed customer expectations and help them succeed in the marketplace.

Optical Component Prototypes of Automotive Lighting Lamps

Our proactive and flexible way of working allows us to fully support automotive lighting development projects. From mechanical component design reviews and photometric development engineering test to show car lamps projects, we create ways to develop the best optical component prototypes in the industry ensures us to provide all our clients with the highest level of automotive prototyping services.

The processing of optical details and the finishing of clear polish are key areas and can significantly affect balances vision with usability in all components design. With more continuous improvement technical skills and advanced equipment, we are capable of processing all kinds of outer lens, inner lens, reflector, light pipes, flat guides, and massive guides in any complicated shapes, which require 3, 4, or 5-axis CNC milling, and even the latest diamond machining technology by Single Point Diamond Machining or Turning (SPDM or SPDT). Then finishes can be achieved the best clarity and light transmittance through our specialized polishing process. The final optical samples are ultra accurate, excellent optical quality and free of any marks or scratches.

Functional Prototyping of Automotive Components

As a specialized prototype manufacturer, WayKen has focused on automotive engineering for a long time and gets great reputation on the functional prototypes of mechanical components. We can provide you with satisfying automotive prototypes manufactured with most suitable way no matter for CNC machining, silicone molding or rapid tooling. In general, automotive functional prototypes development covers these three main purposes:

  • Using the same material as the final parts, realistically simulate the mechanical function, electric performance, thermal properties of the end use product.
  • Creating a more complex prototype of working mechanisms to check form and fit, and ensuring that all parts fit within an assembly.
  • Creating high-precision functional prototypes to measure, compare, or check design errors, dimensional differences and tolerances acceptable.

We utilize a wide range of prototyping technologies and engineering-grade materials combined with traditional hand skills to create accurate and detailed functional prototypes for automotive industry. You'll get professional advice that best suits your needs, whether it is in testing functions and assemblies, or ensuring the feasibility of project manufacturing. This will help to get superior performance data in your rigorous testing scenarios and help prove and perfect your design.

Rapid Injection Molding for Low-volume Production in Automotive Industry

Rapid injection molding provides a better choice for those carmakers and their suppliers needing low volume molded parts. It can not only manufacture hundreds of production-grade plastic parts for verification test close to the final product, but also provide on-demand production of end-use parts for low-volume manufacturing.

At WayKen, we design the rapid solution for automotive development project to bring your product to the final test validation phase. We has years of experience in rapid molds of both aluminum and steel and plastic injection molding, and can rush parts to you on a schedule that supports your entire engineering testing and pre-production schedule. We apply unsurpassed level of expertise to provide cost-effective and rationalized advice from designs, materials, production processes, manufacturability, and predict potential problems to help tackle your engineering difficulties.

Our proprietary process and experienced team focusing on your project enables us to bust the standard industry lead time for tooling and molding. There is no need to compromise and limit your design to our process, because we have the equipment, capability, and knowledge to deliver quality and repeatability on every part.

WayKen Automotive Prototyping Applications

Interior Parts Prototype:

  • Dashboards
  • Consoles
  • Air Vents & Ducts
  • Steering Wheel
  • Central Control Panel
  • Arm Rests
  • Door Panels
  • Speaker Grilles
  • Switch Plates
  • A, B, C & D Pillars
  • Trim Pieces

Exterior Parts Prototype:

  • Bumper
  • Grilles & Grille Covers
  • Emblems & Plates
  • Headlights
  • Taillights
  • Fog Lamps
  • Mirror Housings & Mounts
  • Door Handles
  • Spoilers & Air Dams
  • Trunk Lids
  • Chrome Trim
  • Fenders & Fender Liners

Functional Components Prototype:

  • Air Components
  • Air Filter Housing
  • Engine Cover
  • Shifting Device Lid
  • Battery Components
  • Fuel Tanks

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