Mercedes-Benz CL Coupé 1995
Cutting edge car with elegant lines
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This challenging project, which was awarded to several teams at Bertrandt Sindelfingen in 1995, involved the complete development of outer panelling including body parts and trim, design support at the bodyshell stage, modification of the S-Class saloon's front end and floor areas and the development of the roof and rear panel assembly up to PTS. In the front structural area, support also had to be provided for the supplier developing the front-end module. The prototype centre in Tamm transformed the Class-A outer skin data into practical forms, and was subsequently also commissioned to create the 1:1 data control model (DCM).


All the data for the outer form was created on the basis of the outer form scan supplied by DaimlerChrysler. The main areas were built up using the Syrko CAD system, and curves, joints and flanges were added. The aim was to create a prototype from the surface area data material which would ensure that the first data control model achieved near-series quality.

Design work began at the same time as outer form development. On the basis of the S-Class data and provisional surface-area data from the outer form department, the first investigations could be carried out and geometries drawn up at a very early stage. Even at this stage, the various materials that were to be used in production, and their characteristics, had to be taken into account. Numerous components in the bodyshell have been completely redesigned, with the aim of reducing the car's weight without compromising the active and passive safety or driving comfort. For each module and component of the bodyshell, the most suitable material was chosen in terms of weight, collective load, surface quality and production needs.
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The prototype was then produced from the outer form data for front, rear, roof and bumpers, using our 5-axis HSC milling machine. The milled models were then painted and assembled. The result was so impressive that the DaimlerChrysler executives decided to incorporate the changes resulting from the vehicle's modified design into the existing DCM data. These include changes to the bonnet, side panel and bumpers. Once the DCM series status had been handed over and the end-of-line test on the outer cubing completed, the design team was able to progress at full speed and to adapt development to the finished outer form. After a total of 18 months working on the project, we were able to deliver the design data.
 
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