A Method of Analyzing Gap and Flush Conditions, Visually

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One of the more important areas on a car body are the flush and gap conditions,

this for aesthetic reasons as well as engineering concerns. Making sure all of the parts fit together whilst ensuring they don’t have so much slack that they leave large unsightly gaps that look and feel sloppy to the customer.

For a long time this could be done by engineers with output that consisted of graphs, tables and text. Visual tools have been used as well for mechanical engineering systems such as powertrain components. But what about exterior body panels?

There is a tool that aims to do just that: Aesthetica by Icona Solutions.


What it allows the engineer to do,

is as follows: 1. define the tolerances using GD&T on each part 2. assign a sequence of assembly (how each part is fitted to each part, and in what order) 3. see absolute worst case or statistical worst case results, visually
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Student Feedback

I regularly receive feedback from students who have completed their course and gone on to work in the Automotive Industry. This one is particularly well structured and well written, so I have decided to share it with you. I hope that it will help you understand my course and methods:

Carin: (34) 662 398 525


Student Feedback


I met Graham in 2012 through Learning Alias, at that time  I already knew the basics of  Alias, working  at IVECO Fiat,  so I was  looking for something beyond software training, I was looking for class A training and someone who could demystify it for me!


Graham has been my mentor since then. At that moment my life started to change completely.


Modelling the Audi A5 with Graham’s lessons made me learn all the principals of professional surface construction and built on me the basis  for Class A surfacing. For every part of the exterior hood, fenders, roof, pillars, front and rear ends…there are specific workflow that you cannot learn by tutorials and try to build the model by yourself. You need a professional Alias Instructor to review your model and guide you through each next step as you are confronted by it, and that was the first stage Graham helped me with.


Although it is a path that requires a lot of dedication, when Graham is instructing you, you can feel your progress day-by-day, you stop fighting with the surfaces and start to understand the logic behind them, which curve, which surface comes first and how they should be built.


He taught me the philosophy of the design behind the Audi A5, designed by Satoshi Wada, where the attitude of the car could be represented with 2 character lines, and moreover, could be understood with two brush strokes. That for me was one of the biggest lessons, about simplicity of design, where less is more.


Then once you have mastered the stage 1 (Modelling over blueprints) , on the stage 2 you will enjoy learning the workflows for Reverse Engineering over Polygonal Mesh or .STL, which is a fundamental skill for Class A. When you see a model created by you with nice highlights, patch layout and neat CV hulls, you feel really proud of yourself.

My career had  a great leap forward since I started with Learning Alias. Graham fast-tracked me in such way that in two years I was receiving job offers from Brazil, China, Sweden, and finally from Ford where I work Currently. Alias world is fantastic and as an Alias modeller you will have the gift of being able to create amazing shapes! I am a pro Catia modeller as well, and I can tell you Alias is much more enjoyable, for once you learn through LearningAlias how to customize the software properly you will be able to focus on the design itself and not just on which button you should click!


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Wheel Arch Anti Tangent

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Hi, I’m Kevin de Smet, Elite student group at LearningAlias

I think most of us can imagine the surface-set required to model a wheel arch.

What I would like to put the attention on in this post is the large parent body side surface.

This surface is somewhat special,

in that the trim edge and top natural edge now flow outwards from the top left vertex with an anti tangent relationship (i.e. the opposite of tangent)

First, let’s take a look at the underlying control vertices.

Good. Now, let’s switch to another example

where the modeling was done in a slightly different way. Notice how the anti tangent situation has been avoided altogether by the use of an additional little patch, but that will have left you with a five sided gap that you now somehow would need to fill.

So… some genius, decided to put a power fill function to work, most likely done in a solid modeling package.

Now, surprisingly enough, the highlights on this ridiculous surface look perfect! really, it does!

This is a shot of good fortune, because very often it only manages to generate a surface with forced G2 at the boundaries and a very tumultuous interior to the surface. I can only imagine the solid modeling operator also used additional constraint curves to control the interior of the patch better.

Now, let’s get back to our previous example, with our anti tangent situation. Albeit just in the trim space of a nice clean 4 sided UV structure. By now we have added the fillets along the theoretical style edge.

By this stage in the model, this is now what’s left of that parent surface.

Now, let’s check the tangential continuity relationship

by selecting the top left most point generated by the top natural edge and the trim edge of the wheel arch, using the Curve Continuity function.

As we can see, it now has about 10 degree difference.

It’s still an acute intersection, but it’s perfectly geometrically and topologically legit.

Now let’s look at this model’s top wheel arch patch,

it’s a trimmed out five sided surface just the same as the previous model, but a quick glance at the control vertices and you’ll understand that we didn’t need any power fill to get to where we wanted to be. And this patch we still have under control, it’s a nice added bonus compared to power fills!

I hope this has been informative! Enjoy your Alias

Kevin De Smet

To Learn Alias Automotive to Industry Entry level has been made easier.

For student’s who have the objective of finding a CAD job in the near future, I still teach One to One students and all of these students get Automotive Modeling or Design/Modeling jobs, so it’s a great investment to make. The hourly rate is very high and there are vacancies in UK. France, Germany, Sweden, Spain, USA, Brazil etc. I can only take a maximum of 5-7 students at any one time. I teach all levels right up to Post Graduates. I have never had a Private student fail to get an Alias Automotive job (Companies include Ferrari, GM, Lotus, Opel, Audi Seat etc. ). If you wish to apply for a place, please email me with all your details.
Why not visit my website and take a look for your self?
Over 100 videos on many, many aspects of Learning Pro. Alias
I show you how to build a Complete Audi A5 Sportback (ext.) . Over 50 Videos on that alone !

Info. on Courses:

“Course #1”.

6 Months website access to all website based video tutorials, 167 GBP

“Course #2”.

167 GBP per month. You get your .wire reviewed by me every 15 days and you will receive : feedback, instruction, tips and advice from me personally. Access to all videos including my ” Private Student Training Videos”. You will build at least 3 complete automotive exteriors. The course also includes an intensive Reverse Engineering section, which required by most employers.

“#3 Full Pro. “Elite” Course”.

Fast Track Full Pro. “One to One” Course with weekly reviews and coaching 200 GBP per month. One to One Private tuition. You will receive specific geometry and meshes and modeling from me personally where required, to help you to complete your exteriors quickly to an Industry entry level standard. This means a bigger investment, but once in an Alias modeling job you will get back what you invested many times over and be able to work anywhere in the world

NB: Typically students pay 50% of the cost of the “Elite” course by monthly instalments settling the balance over time,  once they have an Alias Automotive contract.

For more info,

Just register on my website and I’ll send you all the details


If you are in the USA, just register and login, then go to Profile and you can pay your subscription with your US credit card. Absolutely no extra charges for currency conversion.

Discounts for students in emerging Nations. Please ask !


Graham Bullock B.Ed.(CNAA)Des.Tech.

Go to Learning Alias

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Visit My YouTube Channel


There are a total of 163 Learning Alias posts to enjoy on this site

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Audi RS4 Wheel and Tire – Modelling

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  • How to Model an Audi RS4 a Production Wheel and Tyre
  • How to Render it in Alias

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Alias Class A Transitional Surfaces

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Here I’m designing a carbon fiber racing bike frame

and I’ve put together an album of the processes I go through in Alias Studio and the Alias evaluation tools I use to ensure that I have beautifully smooth-flowing transitional surfaces, that give great highlights and will be acceptable to the client. Please share my page. thank you ! Please share my page. 请分享我的网页。


Adjusting the shape of each transition surface, using the direct history of the curves and the Tangent Align Control. 调节每个过渡表面的形状,利用该曲线与切线对齐控制的直接的历史。


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Computer Aided Design – Working from Sketches


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CAS modeling methodology.

Acknowledgement: All the below work has been produced by a very talented and competent Design/Modeler Bradley Ratajczek.

Bradley’s education:

Bachelor of Industrial Design (with Honours) Major in Transportation. Monash University, Australia

Diploma of Arts (Product Design), RMIT, Australia

Bachelor of Arts (Transportation Design) ,Academy of Arts University, San Francisco, California

Bradley has Australian and USA passports and is currently seeking an Entry level contract. Please message me if you want to interview him. You can also message me thru my teaching website: www.learningalias.co.uk

The Alias modeler is given anything between one and 4 sketches of the design intent by the designer.


The designer works closely with the CAS modeler to convey the design intent verbally


Some designers have time and consideration and supply the modeler with detailing sketches


Other times the info from the designer is sparse ae shown in the pic. below


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