Bonded Hybrid Front-End Systems - An Approach to Design and Platform Strategies

There are two main requirements for a front-end carrier (FEC). One role is to integrate various components like the cooling unit, headlights, latches and other parts into a front-end module. The main driver behind the modular approach is the need for a lean production process in the OEM plant. The ability to easily build design variants offline is an extra benefit. Design variations in the field of front-end modules are linked to the colour and style of the bumper fascia, size of the cooling unit, headlamp style and various other factors. In the end the modular approach leads to cost savings during the production process and higher quality.

The other role of the FEC is to provide structural performance to resist various mechanical, thermal and chemical loads.

This paper outlines an approach that enables flexibility of design while ensuring the performance of the system.