A Method of Analyzing Gap and Flush Conditions, Visually

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Hi, Have you just completed a disappointing Alias course at Uni? Can’t get an entry level job because you don’t know enough about Alias Class A Modelling and Reverse Engineering. This is normal because universities can’t afford to employ top Alias Automotive modellers. Please don’t worry, you’ve found the right website. If you need PROFESSIONAL online Alias Automotive and Reverse Engineering video training + regular help and reviews to Industry Entry level ( A Class Principles), please register on my website for free and I will send you the course details: I have a 100% success rate at finding an Alias position with students who complete the course.


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


Tolerances that are shown to contribute less than expected can be increased, benefiting manufacturing costs. On the other hand, tolerances that are shown to be too loose can be tightened, increasing the quality of the car. This in an effort to not break the bank, as without tools like this many parts would be too tightly toleranced leading to unnecessarily increasing costs that ultimately nobody benefits from.

You can see this in action at the website of Icona: http://www.iconasolutions.com/Demonstration_Videos.aspx
You will need to register but this is totally free of charge.

Now, the question remains: should this be in the hands of the designers/stylists or engineers? In my opinion: both!
Design wants could get lost if only engineers do these kinds of validations, whereas engineering needs could be lost or complicated if it was purely up to designers/stylists.

Despite them being two very different worlds, if both can communicate with each other visually, on a digital mock-up. There is a good chance a better end product will be the result. Of course this is all still on the computer and the results Aesthetica will give you, will only be as good as the inputs you enter into the system. It’s just a tool. But if used well, it’s one hell of a ride!

Thank you for your time,
Kevin De Smet – “Advanced LA Student”

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 (224 USD equivalent Sept. 2012)

“Course #2”.

167 GBP (224 USD equivalent Sept. 2012) 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 (USD. 268 approx. Sept. 2012) 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 installments 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.


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

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