Audi TT

For all senses
The Audi TT already conquered the hearts of car enthusiasts as a roadster and coupe in the first generation and became a design icon with cult status. The second generation does not have to take second place. Thus, for example, the coupe was already chosen as the “most beautiful car of the world” as well as the “most popular car in Germany” by readers of some car magazines”. Was there a special requirement in the development of the new generation? The TT successor had to be recognised as a TT at first sight. At the same time the car should make a more modern and grown up impression. Evolution instead of revolution, this was the maxim. Bertrandt Neckarsulm accompanied different body-in-white and interior scopes from the concept phase up to market launch.

From the concept up to series production

The Audi TT Roadster’s car trunk surface was solely developed by Bertrandt.
Processed interior scopes of the Audi TT coupe car trunk.

Whether with the flaps, the exterior or interior - in the TT project - to Bertrandt Neckarsulm it was a matter of indicating high interface competence for the most different development periods. The assignment consisted of the elaboration of the front flaps, fenders and the car trunk for the coupe and roadster as well as comprehensive panelling parts in the interior; from the concept phase up to series production. Further Bertrandt supervised the concept phase of the bumper development. The designers were especially challenged with the car trunk surface for the Audi TT roadster which was developed solely by Bertrandt Neckarsulm and was coordinated with the Audi interior design. Another challenge consisted of the design for manufacturing, because the component spectrum presents itself very variously. Whether injection moulding in connection with internal gas pressure, concealed fibre groups or lightweight construction materials, metal pressing and join technology - every production procedure required the most different parameters. Together with the Audi specialised divisions and system suppliers, all tasks were solved according to the most current state of technology. The service package was completed by means of the design FMEA, which Bertrandt Neckarsulm accompanied together with the nominated system suppliers. In a supporting capacity, the colleagues from Neckarsulm made the most different prototype parts and cooperated in the series production across the Engineering Services Competence Centre Györ.

Carry-over-parts challenge
The COP idea (Carry Over Parts) anchored in the VW group (Carry Over part) was lived out in the entire project. Because both vehicles are only partly identical, a special focus was on the investigation and logical implementation of the same part idea. In order to generate solutions to minimise existing partial differences as much as possible or to absorb them by means of managed manufacturing methods, stood in the foreground. On this occasion, the goal was to allow a very optimum cost situation or rather partial logistics. This Bertrandt implemented in the interior range in the development of the car trunks, tool box as well as lower columns and door sill panelling for the coupe as well as for the roadster. In addition, the engineers took into consideration different body-in-white variations and in the roadster different concealing variations. Specific features particular for different countries were to be taken into consideration also; as for example a special tools box variation for the USA in order to obstruct the prescribed active coal filter or preparation for the fixing of a smoke candle in the lower column panelling for the Japanese market which assumes the function of a warning triangle.

Sophisticated Project Structure
On account of the various tasks, up to four project teams worked on this project within the development period in different development stages. Regular coordination rounds guaranteed optimum and easy communication in the project between the single teams, competence centres and system suppliers at any time. Especially in focus was; in addition to the communication with the customer and the Bertrandt project teams; the uniform documentation for the whole processing period. This action enabled to represent the project progress strictly in every phase. The Bertrandt teams also co-operated subsidiary-wide, especially in the range of the front flap development by which the requirements were to be taken into consideration for pedestrian safety. Through the flexibility and the know-how of all employees involved in the project, Bertrandt Neckarsulm could fulfil the individual wishes of the AUDI AG at any time. In conclusion, the Audi TT is a vehicle on the streets which justifiably demonstrates the desire for the joy in unusual things.