TRASCO OEM engineering, armoring design in CATIA

OEM engineering: from concept to series production

From the first draft to prototyping right up to the finished product, implemented by experienced TRASCO design engineers.

OEM standard toolchain

Designed like a series vehicle.

Our engineering department works on up-to-date 3D CAD workstations with CATIA V5, the standard software of the automotive OEMs we supply, together with Autodesk Inventor, a Creaform 3D scanner and FEM calculation software. The armoring cage is integrated virtually before manufacturing starts.

3D scanning and imaging allow our design engineers to integrate the various levels of armor precisely into an existing vehicle structure, for the highest level of structural integrity and a finished product that looks like it left the factory.

TRASCO engineer scanning a vehicle body with a 3D scanner

The process

From the first draft to series production

01
Requirements

Protection level, weight budget, equipment and timeline are defined together with the OEM, based on the vehicle and its intended use.
02
3D scanning

The base vehicle is scanned in 3D, so the armor can be integrated precisely into the existing body structure.
03
Design in CATIA V5

Armoring cage, extensions and equipment are designed in the OEM standard software CATIA V5 and integrated virtually before any part is manufactured.
04
FEM calculation

Stress and stiffness are verified with FEM calculation software, from hinges and door arresters to suspension components.
05
Prototype & testing

The prototype is built in-house and tested: driving tests, strength tests, TÜV inspections and, where required, full VPAM ballistic and blast certification.
06
Series production

After release, the design goes into production, from individual vehicles to small series of components, assemblies and complete vehicles.

Suspension development

Stronger parts where the series part reaches its limit.

The added weight of the armor puts loads on the chassis that series parts are not designed for. TRASCO evaluates the critical components, engineers improved parts and verifies them with a worst-case FEM analysis against the original. TRASCO further develops suspension systems or designs them from scratch, in some cases in cooperation with universities and specialized partners.

The improved components are made of high-tensile stainless steel, and every TRASCO suspension part goes through a testing phase and component approval before it is used.

Weight-optimized series component: worst-case FEM analysis
Improved component, designed by TRASCO
Improved component: worst-case FEM analysis

FEM analysis of a steering knuckle
Heavy-duty brake system on an armored SUV
Reinforced rear suspension with heavy-duty shock absorbers and stabilizer

Testing & traceability

Measured, tested, documented.

On the test track

Prototypes are driven on the test track and measured against the unarmored base vehicle: acceleration, braking distance, double-lane change and slalom.
Ballistic and blast tests

For tests to VPAM and STANAG, TRASCO builds prototypes for complete-vehicle tests and vehicle components for design and structural tests, tested by independent test institutes.
Traceable protection components

All protection components are monitored and traced through production, and all of them go through an additional ballistic quality assurance.