Opel Zafira OPC

Powerful sportvan with distinct forms
The Zafira OPC captivates at first sight: Dynamic lines support the sporty appearance, suggesting driving fun and superior performance. Clear the way for the sportvan, for those of you who don't just want driving to set their pulse racing. The proof of this is confirmed by some of our colleagues who have already experienced the effect of its dramatic curves.

Scope of the project
In the summer of 2000, Zender Industrieprodukte GmbH received an order from Opel Special Vehicle GmbH (OSV) to develop the complete exterior sports kit for the Zafira OPC. For its part, Zender chose Bertrandt to be its expert development partner for the project. The components involved include the development of the front and rear bumpers, wheel housing plates front and back, trim and the sill and tailgate plates. Between June and November 2000, data was scanned, the surfacing and data control model (DCM) generated and the components designed at Bertrandt. Bertrandt Rüsselsheim acted as the interface for all involved - Zender, Opel International Technical Development Center Special Vehicle Engineering (ITDC SVE), ITDC Design and three other Bertrandt branches.

Digitalisation in Tappenbeck
The go-ahead for Bertrandt came mid-June 2000. Bertrandt Tappenbeck scanned in the clay model created by Zender. To do this, the Tappenbeck team worked with GOM-Atos, a highlysensitive photo-optical scanning system. The data obtained was passed on to colleagues in Cologne.

Surfacing at Bertrandt Cologne
The entire surface development of the components took place at Bertrandt’s branch in Cologne using ICEM-Surf software. Within six weeks, the surfaces on the Tappenbeck colleagues’ points cloud were created. Since the zero data from the scan can deviate and cannot always be implemented as a tool, Bertrandt Cologne polished the surfaces to ensure feasibility and quality. After a lot of going to and fro between the engineers and designers, the surfaces of the vehicle were brought in line.

Component design and supplier management in Rüsselsheim
Using the surface data, the toolbased design of the components and connections on the vehicle was carried out at Bertrandt’s Rüsselsheim branch. In this way, the Bertrandt branch in Rüsselsheim was the interface for the magic triangle, OEM - supplier - development partner, for the duration of the project. Coordination of the Bertrandt branches, the Opel areas of Styling and Special Vehicle Engineering and Zender took place from this site. At joint project meetings, the current status of the various areas was always assessed and the next stages of the project discussed.

Data control model from Ehningen
The Ehningen model builders produced the data control model from the data obtained from the surface development and the first connection designs. The DCM served as the basis for the design freeze which took place in September. Thanks to the rapid generation of the DCM, the Rüsselsheim branch was able to use the toolbased development of the data and meet the planned handover date of the approved component data to Zender at the end of October. In November, Bertrandt officially completed the project with the production of the drawings. Due to the good cooperation between the project partners, the prototype was presented at the Geneva Motor Show in March 2001.

Summary and outlook

The interface management of the Zafira OPC project took place across several Bertrandt branches. The successful running of the project confirms that the Bertrandt Group works as a network internally and can guarantee the customer the best possible output based on the specialist knowledge of the various branches.

Bertrandt would like to thank Zender and Opel for their co-operation and the company looks forward to working together on the next project. Due to the success of the Zafira OPC, Opel is offering a styling kit as a facelift for all engine variants - designed and developed with Bertrandt.