Prototyping For Automotive Engineering Applications

Single prototypes tell you nothing about system reliability. Modularity is the secret key you're missing. When we built the multi-function demonstrator for Hyundai Cradle, we created a series of modular prototypes. Each targeted at validating specific performance vectors. → Thermal modules tested for uniformity and delta-T across surfaces → Touch and switch modules evaluated for actuation force versus signal-to-noise ratio → Pressure sensing modules designed to maintain accuracy under cyclic compression and lateral shear Key variables we isolated included: → Material stack-up compression profiles during environmental cycling → UV adhesive bond stability across operational temperature bands (-40°C to +85°C) → Electrical resistance drift under flexural fatigue testing (bend radius <5mm, 10,000+ cycles) By modularizing early, we could: → Identify failure modes before scaling → Fine-tune adhesives, conductors, and substrates independently → Model manufacturing tolerances with real data, not assumptions In hardware, scalable design isn’t about the first build. It’s about how you architect your prototyping process.

As modern vehicles rapidly evolve into intelligent, connected systems, the demand for secure, resilient, and scalable communication architectures like RAMN (Resistant Automotive Miniature Network) is accelerating. But full-scale prototyping often comes with high cost and complexity. That’s why our latest blog from the VicOne team, authored by our CyberThreat Research Lab, @Florengen Arvin Parulan, explores how engineers and innovators can replicate the core functions of RAMN using just a single STM32 board. Why this matters: ✅ It lowers the barrier to experimentation and education. ✅ It allows teams to simulate real-world ECU networks affordably. ✅ It provides a valuable platform for testing error handling, data routing, and cybersecurity protocols before full deployment. As the industry races toward software-defined vehicles, the ability to test fast, test smart, and build securely will define tomorrow’s leaders. This hands-on project proves that even simplified tools can deliver deep insight — and spark the next generation of resilient, secure mobility systems. 📘 Dive into the full blog for setup steps, advantages, and limitations of this single-board approach: 🔗 https://lnkd.in/e7Bbn9gY 💡 Whether you're a Tier 1 engineer, a security researcher, or just curious about automotive innovation, this is one to check out. #AutomotiveCybersecurity #SDV #InVehicleNetworking #STM32 #EmbeddedSystems #ECU #CANBus #RAMN #CyberResilience #IoT #SecureMobility #VicOne #InnovationInMotion #AutomotiveEngineering #CaptureTheFlag #CyberEducation #TechForGood

A $12 prototype can make $50,000 of engineering analysis look ridiculous A team of engineers was stuck on a bearing failure analysis for six weeks. Vibration data, FFT analysis, metallurgy reports - they had everything except answers. The client kept asking for root cause and the engineers kept finding more variables to analyze. Temperature gradients, load distributions, contamination levels, manufacturing tolerances. Each analysis created more questions. Then the intern did something that made the engineers feel stupid. She 3D printed a transparent housing and filled it with clear oil so the engineers could actually see what was happening inside the bearing assembly. Took her four hours and $12 in materials. They watched the oil flow patterns and immediately saw the lubrication wasn't reaching the critical contact points. All their sophisticated analysis was based on assuming proper lubrication distribution. Wrong assumption. Six weeks of wasted effort. The visual prototype didn't just solve the problem - it changed how the engineers approach these types of investigations. Now they build crude mockups before diving into analysis rabbit holes. Cardboard, tape, clear plastic, whatever works. Physical models force you to confront your assumptions before you spend weeks analyzing the wrong thing. Sometimes the cheapest prototype teaches you more than the most expensive simulation. #engineering #prototyping #problemsolving