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AM-002 · Alchemy Nano · Industry / Analysis
Windshield Protection Film Mould Design
Scan-to-production workflow for Tesla and BMW windshield protection film (WPF): 3D scans verified in CloudCompare, surface-modelled in SolidWorks and released as production thermoforming moulds.
- Production moulds
- 8+
- Cycle time cut
- 15%
- First-time yield
- +10%
01What
- Reverse engineered windshield geometry from high-precision 3D scans for Tesla and BMW windshield protection film (WPF) programs
- Owned each mould end to end: scan mesh, CAD, PLM release, validation and final-product testing
- Goal: moulds accurate enough that the formed film fits the glass with minimal manual fitting
02How
- Captured windshield geometry with Einstar 3D scanners and compared repeat scans in CloudCompare (deviation maps and histograms) to verify accuracy
- Improved scan-to-scan consistency so the surface model was built from verified data, not a single noisy capture
- Surface-modelled the glass and designed production thermoforming moulds in SolidWorks, released through PLM
- Built a Python pipeline to automate scan refinement and meshing
- Ran forming trials, tuned temperature and pressure profiles and revised dies from the test results
03Results
- 8+ production-grade moulds released and manufactured from the CAD drawings
- Cycle time cut 15% and first-time yield raised 10% through trial-driven process and die changes
- Manual scan refinement and meshing time reduced 20% by the Python pipeline
- Dimensional accuracy and surface quality verified in testing; workflow adopted for ongoing production
Tools & methods
SolidWorksEinstar 3D ScannerCloudComparePythonPLMThermoforming