Opening Doors for Supercars

A supercar manufacturer needed fixturing and machining for four different aluminium castings forming a lightweight door-opening mechanism, parts that had to assemble perfectly while keeping weight to an absolute minimum.

Four separate castings meant four sets of variability, all of which had to resolve into one mechanism that moved flawlessly. Tolerance stack-up was the enemy.

We designed dedicated fixturing for each casting that referenced common datums, so all four parts were machined to a shared coordinate framework, controlling the stack-up before it could accumulate.

Machining strategy preserved the thin, weight-optimised sections while holding the critical interface tolerances that let the mechanism move freely.