From crisis to recovery

The ACEA Economic & Market Report – Full Year 2024 highlights that the European automotive industry faced one of the most severe crises in decades during 2022–2023. Car production in the European Union fell by 6.2% in 2024 compared to the previous year, with the report emphasising that the sector operated under “less certainty than the rest of the industry.” Key factors included semiconductor shortages, rising energy costs, and inflationary pressure.

Data from CLEPA (European Association of Automotive Suppliers) also confirms the scale of the challenges. In 2024, automotive suppliers reported 54,000 job losses – more than during the pandemic years. Moreover, in just the first quarter of 2025, a further 10,000 jobs were cut. These figures show that cuts in engineering and production functions were not temporary, but a sign of deep restructuring within the industry.

Still, data from 2025 shows that the situation is beginning to shift. According to KPMG’s Global Automotive Executive Survey 2025, manufacturers are once again increasing investment in strategic areas such as electromobility, software development, and ADAS systems. This not only signals a rebound in the market, but also a surge in demand for highly skilled engineers, especially in fields such as e-mobility, lighting, and interior design.

The tlent gap: a real threat to projects

Companies that downsized during the crisis now face a pressing challenge. The growing volume of orders for electromobility and ADAS-related projects requires experienced engineers – but many organisations lack them.

Hiring from scratch is both lengthy and costly, while delays risk lost contracts or declining customer trust. There is also the danger that new hires may not adapt to the demands of a complex engineering environment or fail to meet OEM expectations.

Compounding the issue, many professionals who left the automotive industry during the downturn have since found stable roles in other sectors – and do not plan to return. This deepens the skills gap even further.

A solution to engineering shortages

As the number of new projects increases, companies are increasingly turning to alternatives to traditional recruitment and the expansion of internal R&D departments. One of the most effective solutions is nearshoring – outsourcing engineering services to specialised external providers located in the same or nearby geographical regions.

This enables collaboration with teams operating in the same time zone, who understand European quality standards and regulations, while offering greater flexibility than internal R&D functions.

Partnering with an engineering company such as Endego ensures:

• access to teams of experienced engineers,
• flexible scaling of resources depending on project needs,
• a blend of domain expertise (e.g. lighting, e-mobility, interior design) and practical experience,
• project execution in line with OEM requirements and industry standards.

With nearshoring, manufacturers and suppliers can respond rapidly to market recovery – avoiding lengthy recruitment cycles and minimising the risks of staff shortages.

A new balance in the automotive industry

The automotive market is entering a new phase of transformation – moving from crisis, through recovery, towards dynamic growth driven by electrification and software-defined vehicles (SDVs). In this environment, flexible engineering collaboration models are becoming a cornerstone of competitive strategy.

Nearshoring enables companies to adapt seamlessly to changing market conditions, without excessive costs or long recruitment processes. It is not only a way to quickly fill staffing gaps – above all, it is a guarantee of project continuity and quality, which now define manufacturers’ market positions.

At Endego, we have been supporting the automotive industry for years, delivering comprehensive design and engineering services – from concept and simulation to software development and series production implementation. We offer services under the following cooperation models:

• Talent as a Service (TaaS) – rapid team scaling, with the option to assign full teams or individual specialists, managed either by the client or Endego.
• Solution creation service – delivery of ready-made solutions on a fixed-fee basis, aligned with predictive or adaptive project life cycles.
• Dedicated client team – building and managing a tailor-made team with an optional transfer model (B.O.T.), ensuring full control over the project.

Our teams provide expertise across key domains, including:

• vehicle body,
• interior,
• lighting & optics
• wiring​ harness,
• software & hardware,
• CAE,
• powertrain systems.

Contact us today to discover how nearshoring can boost your engineering capacity, safeguard project continuity, and ensure the highest delivery quality.

Sources:

• https://www.acea.auto/files/Economic_and_Market_Report-Full_year-2024.pdf
• http://kpmg.com/xx/en/our-insights/transformation/annual-global-automotive-executive-survey.html
• https://www.clepa.eu/insights-updates/data-digests/clepa-data-digest-18-job-losses-escalate-as-demand-stays-below-expectation/
• https://www.clepa.eu/insights-updates/data-digests/factory-closures-overshadow-eus-mobility-transition/

In this article, we explore:

• how decorative LEDs are reshaping automotive design and brand identity,
• the communication functions light performs in vehicles,
• the technical and regulatory challenges manufacturers face,
• why decorative lighting supports sustainability strategies,
• what innovations are just around the corner.

From halogen to OLED

The development of lighting technology is one of the most dynamic changes taking place in the automotive industry. The path has led from simple halogens, through xenons, to LEDs, which currently dominate the market. The next step is OLEDs and micro-LEDs, which enable the creation of very thin, light and flexible light sources. Examples of such innovations are our projects, including an advanced prototype of OLED lighting.

In addition to its key importance for safety, lighting has also become important as an expression of creative design. This is a natural development of the broader trends we described in the article: Designing the automotive lighting of the future: trends, challenges, and opportunities.

Decorative LEDs in cars as a brand differentiator

What seemed extravagant not so long ago is slowly becoming the norm today. Illuminated logos, illuminated front grilles, and illuminated door sills and illuminated boot trim are appearing in an increasing number of models – from premium brands to electric car manufacturers, for whom the ‘wow’ effect is an important element of communication with customers. Here, light is more than decoration – it has become a new design language.

Lighting as part of the user experience

Today, exterior lighting elements shape the user experience, complementing the ambient lighting used in the interior. The welcome effect, smooth colour transitions and visual signals informing about the vehicle’s status (e.g. EV charging status indicated by the colour of the logo) allow the car to communicate with its surroundings in an intuitive way. This seamless blend of design and functionality brings the automotive industry closer to the world of consumer electronics.

Technical and regulatory challenges

However, the implementation of decorative LED lighting requires addressing a number of challenges.. Engineers must fit the installations into a limited construction space and ensure their durability in conditions of humidity, high temperatures or the impact of road salt. A good example of this approach is our design for an innovative rear lighting variant, in which we have combined design requirements with stringent reliability standards.

Legal issues are also important – regulations regarding brightness, colours and lighting methods vary from region to region, and some light animations require homologation. You can learn more about combining safety with visual appearance in the article: Design and safety – the design of automotive lighting.

Energy efficiency is another challenge: in electric vehicles, every additional feature affects the range.

Sustainability and innovation

Manufacturers are also increasingly emphasising the ecological dimension of modern lighting. LEDs consume significantly less energy than traditional light sources, and the development of OLEDs and micro-LEDs further reduces the weight of components and their energy requirements. The use of recycled materials in the production of luminaires and diffusers is growing. As a result, decorative lighting not only enhances the attractiveness of the car, but also supports the sustainable development strategy of OEMs.

The future of decorative lighting

The coming years will bring even greater opportunities for personalisation. The colour and intensity of the light, as well as the animations created with it, will be able to change depending on the driving mode or the driver’s preferences. Interactive solutions will emerge, such as lighting that communicates with other road users as part of V2X systems. Attempts to standardise light animations can also be expected, which will prove particularly important in the context of autonomous mobility – light will become a universal language between the vehicle and its surroundings.

Light as a new brand language

Decorative LEDs in the automotive industry are more than just a design accessory. They are a strategic tool for building brand recognition, shaping emotions and communicating with the user. This trend is not slowing down – on the contrary, it is entering a new phase of development with OLEDs and micro-LEDs. For manufacturers, this means combining design creativity with rigorous technical standards, and for customers, it means a completely new experience of interacting with their car.

At Endego, we support manufacturers in the design and implementation of modern lighting solutions – from design concepts and simulations to software development. You can learn more about our projects from case studies such as:

• precision in design: Endego rear lamp for series production,
• comprehensive development of an electronic rear light system,
• precision software for automotive front lighting,
• advanced Endego software for car headlights.

If you are interested in innovative solutions in the field of automotive lighting, please contact us. Together, we can create solutions that combine design, technology and reliability.

MK Seats GmbH  

Task:

The client requested verification of a regional train driver’s seat to ensure compliance with VDI 2230 guidelines for bolted joints, taking into account the loads defined by VDV 152. Additionally, the task included optimisation of the bolted joints for strength in case the criteria were not met.

Solution:

An advanced FEA model of the seat was developed, including a detailed representation of the bolted joints. A comprehensive strength analysis of the structure and joints was performed in accordance with relevant industry standards. In close collaboration between the MK Seats team and ENDEGO CAE experts, the bolted joints were optimised, ensuring full compliance with strength and technological requirements.

Result:

The outcome was an optimised and validated driver’s seat design, guaranteeing safe and reliable operation for many years. This enabled the client to expand its portfolio with more complex solutions for the railway sector and strengthen relationships with a key OEM.

In this new landscape, the High Performance Computer (HPC) is becoming the vehicle’s “brain” – orchestrating domains such as powertrain, infotainment, ADAS, and charging. In practice, it’s a data centre on wheels. The more performance, connectivity, and integration it has, the greater the cybersecurity challenges.

Where the security challenges start

System complexity

Modern vehicles blend multiple technology stacks – Linux for infotainment, Android Automotive for user experience, AUTOSAR Classic/Adaptive for safety-critical domains – all interconnected via networks like CAN, Ethernet, and LIN. Each stack has its own vulnerabilities, patch cycles, and dependencies. The result? A huge attack surface, with complexity amplified by zonal architectures and remote connectivity (Wi-Fi, Bluetooth, 5G, V2X).

External libraries and dependencies

Many vehicle features rely on third-party libraries or open-source software. These speed up development but can introduce vulnerabilities outside the OEM’s direct control. If a supplier delays a patch, the risk remains in the system until mitigated.

Regulatory requirements

For engineers and architects, compliance is not just paperwork – it’s a design constraint.

• UNECE R155 mandates a Cybersecurity Management System (CSMS), covering the entire lifecycle: from concept and design to post-production monitoring and decommissioning.
• UNECE R156 requires a Software Update Management System (SUMS) to securely deliver and verify updates over a vehicle’s lifespan.
• ISO/SAE 21434 translates these into engineering practices – from Threat Analysis and Risk Assessment (TARA) to incident response planning.
• ISO 24089 adds requirements for secure OTA update processes.
• FIPS 140 defines cryptographic module security requirements, crucial for hardware and software crypto in vehicles.
• Radio Equipment Directive (RED, EN 18031-1/2) imposes additional requirements for wireless-capable devices, mandating robust cybersecurity and resilience against network attacks.

The real challenge is embedding these into architectures that already juggle safety, performance, and cost targets – all under tight market deadlines. Non-compliance? The vehicle can’t be sold in many key regions.

Cybersecurity vs. ASPICE and development deadlines

Integrating security into established ASPICE-based development processes can be a challenging task. Cybersecurity tasks — such as code audits, threat modelling, and secure configuration checks – often add work that isn’t visible to end customers but is critical to system security and safety. Balancing these invisible tasks with delivery deadlines is a constant tension.

 Invisible work problem

Security engineering rarely produces visible “features” for customers. Implementing secure boot, encrypting data at rest, or hardening an OTA pipeline takes significant time but doesn’t change how the car looks or drives. This can make it harder to justify resources internally – even though these measures are essential for protecting the brand and the user.

What hackers do – common attacks on vehicles

Attacks can target internal networks, external interfaces, hardware, or backend infrastructure. Real-world examples include:

• CAN bus injection – exploiting lack of authentication to send malicious frames (DoS floods, fuzzed messages, impersonation, or Bus-off attacks).
• ECU reprogramming – flashing modified firmware to bypass controls or add backdoors.
• Sensor data spoofing – feeding false GPS, radar, or camera data to mislead ADAS/autonomous systems.
• Keyless entry relay attacks – extending fob communication range to unlock/start without the key.
• Wireless exploits – attacking Wi-Fi, Bluetooth, 5G, or V2V/V2I channels to pivot into critical systems.
• OTA update compromise – injecting malicious code or exploiting weak rollback protection.
• Backend breaches – compromising OEM or supplier servers to distribute malicious updates or manipulate telematics data.
• Hardware attacks – side-channel attacks on chips, fault injection, or physical tampering to extract keys or bypass security features.
• Supply chain compromise – introducing counterfeit chips, backdoored components, or malicious firmware during manufacturing or logistics.

These can be carried out by opportunistic thieves, organised cybercriminal groups, hacktivists, or state-sponsored actors – each with different capabilities and goals.

Day-to-day in automotive cybersecurity

Automotive cybersecurity is a constant cycle of anticipating threats, building defences, and responding to incidents. It starts with TARA to identify where the highest risks are, from infotainment systems to safety-critical controls, guiding design priorities. Engineers then implement measures such as:

• Secure boot – only trusted, signed code can run on ECUs/HPCs.
• Secure diagnostics – access to sensitive functions is restricted to authenticated tools.
• Secured communications – TLS, Secure Onboard Communication (SecOC), and strong key management.
• Secure OTA updates – digitally signed, encrypted, rollback-protected.
• Physical hardening – disabled debug ports, encrypted firmware.

Security is validated through penetration tests, fuzzing, audits, and code reviews, all aligned with ISO/SAE 21434 and regulatory requirements. Increasingly, vulnerability scanning and management tools are integrated into the CI/CD pipeline, automatically scanning each build and feeding fixes into the development backlog – ensuring that known issues are addressed before they can be exploited.

After production (SOP), continuous monitoring via Intrusion Detection and Prevention Systems (IDPS) and Security Operation Centres (SOC) helps detect anomalies in real-time, ensuring readiness for the worst-case scenario.

Core security principles

• Defence in depth – hardware + software + processes + supply chain controls.
• Security by design – integrate security from the concept phase.
• Regular updates – because vehicle lifecycles outlast many software vulnerabilities.
• Continuous monitoring – detect and respond before an incident escalates.

Final thoughts

Automotive cybersecurity is not a “feature” – it’s a continuous, evolving discipline that spans the full vehicle lifecycle: concept, development, production, operation, and decommissioning. It requires coordinated effort across OEMs, suppliers, regulators, and cybersecurity experts.

The vehicles of the future will be more connected, autonomous, and software-defined than ever before. Without robust, embedded security, they’ll also be more vulnerable. Getting it right isn’t just about compliance – it’s about safety, trust, and brand survival in the next era of mobility.

Sources:

• https://www.researchgate.net/publication/382736828_Automotive_Cybersecurity_Challenges_A_Practitioner’s_Guide
• http://www.diagnostyka.net.pl/Author-Piotr-Pe%C5%82echaty/284817

Walter Wagner, Sales Director at Endego, works at the forefront of modern rolling stock design, simulation, and modernization. From lightweight materials to digital modelling, his focus is on delivering efficient, sustainable solutions that meet the complex demands of today’s operators – and tomorrow’s passengers.

Jan Scheepers, Sales Manager Europe at Ricardo Rail, ensures that every new system or technology entering the rail network is safe, compliant, and ready for real-world conditions. With expertise spanning ERTMS, signalling, system validation and certification, his role is to ensure innovation is not only possible – but reliable.

Together, they offer a unique perspective: one focused on engineering innovation, the other on system-level assurance. It’s a combination that brings real value to complex rail projects – from design to delivery.

In this interview, they share their views on the trends, challenges, and strategic shifts reshaping the railway sector – and how collaboration is becoming essential to move forward with confidence.

Let’s start with a broad view… How do you see the railway industry evolving today, and where do you think it’s headed in the near future?

Walter Wagner: The railway industry is undergoing a significant transformation, driven by the need for sustainability, digitalisation, and integrated systems. We are seeing increased investment in electrification, automation, and innovative technologies, aiming to improve efficiency and reduce environmental impact. The future of rail is interconnected, with seamless integration between different modes of transport and advanced data analytics shaping operations.

Jan Scheepers: I agree with Walter. The industry is moving towards more sustainable and safe solutions. Please don’t forget interoperability, ERTMS and standardisation. There is a growing emphasis on reducing carbon emissions, enhancing safety, and improving passenger experience. Technologies like hydrogen and battery propulsion, digital twins, and automation are becoming central to the development of future rail systems.

Looking back over the past 5–10 years, what are some of the most significant shifts or changes you’ve seen in the rail sector?

Walter Wagner: Over the past decade, we’ve witnessed a shift from traditional rail systems to more integrated and intelligent networks. The adoption of digital technologies, such as predictive maintenance and real-time monitoring, has enhanced operational efficiency. Additionally, there is a stronger focus on sustainability, with increased investments in electrification and renewable energy sources.

Jan Scheepers: The most notable change has been the industry’s commitment to sustainability on one hand. There is a clear push towards reducing emissions and energy consumption. This has led to the development of alternative propulsion systems, like hydrogen fuel cells and battery-electric trains, as well as the implementation of energy-efficient technologies across rail networks. Interoperability with the ERTMS pillar in particular has led to a significant challenge as well.

How are those changes impacting the way rolling stock is designed, developed, or validated today?

Walter Wagner: The shift towards sustainability and digitalisation has significantly influenced rolling stock design. Designs now incorporate lightweight materials, energy-efficient systems, and advanced control technologies. Simulation and digital modelling play a crucial role in optimising designs and ensuring compliance with evolving standards.

Jan Scheepers: From a sustainability and interoperability perspective, these changes mean that the sector must adapt the processes to accommodate new technologies and standards. We are increasingly involved in the early stages of projects, assuring that designs meet safety and performance criteria before implementation.

In light of those evolving challenges, how is your company adapting its approach to engineering, compliance, or innovation?

Walter Wagner: At Endego, we are embracing digital transformation by investing in advanced simulation tools and developing expertise in emerging technologies. Our approach is centred around flexibility and collaboration, allowing us to respond swiftly to industry changes and client needs.

Jan Scheepers: Ricardo is enhancing its capabilities in system assurance by integrating digital tools and methodologies. We are focusing on developing a deeper understanding of new technologies to provide comprehensive validation and certification services that support innovation while ensuring safety and compliance.

Which emerging market needs or passenger expectations are having the most significant impact on rail development today?

Walter Wagner: Passengers are increasingly expecting faster, more reliable, and environmentally friendly services. This demand is driving the development of high-speed trains, improved scheduling systems, and the integration of multimodal transport options. It also needs international alignment and actions with a common purpose.

Jan Scheepers: Passenger expectations are also influencing the focus on comfort and accessibility on one hand and sustainability and interoperability on the other hand.  There is a growing emphasis on designing trains that are not only efficient but also provide a pleasant and inclusive experience for all passengers. Battery, hydrogen propulsion, and ETCS will have a key impact.

And how are those already shaping the way your teams approach engineering, design, or validation?

Walter Wagner: We are adopting a user-centric approach in our designs, ensuring that passenger comfort and accessibility are integral components. Our teams are also leveraging data analytics to optimise performance and maintenance schedules, enhancing overall service quality.

Jan Scheepers: Our validation processes are becoming more dynamic, incorporating real-time data and simulations to assess performance under various conditions. This approach allows us to anticipate potential issues and address them proactively, ensuring that the final product meets passenger expectations. We are investing in sustainability and ERTMS knowledge.

Railways face growing pressures around safety, cybersecurity, and operational resilience. What are some of the key risks or vulnerabilities your teams are helping to address in rolling stock or system design?

Walter Wagner: One of the key risks is the integration of new technologies without compromising safety. Our teams are focused on designing systems that are both innovative and secure, incorporating robust cybersecurity measures and ensuring compliance with safety standards.

Jan Scheepers: Cybersecurity is a critical concern, especially as rail systems become more interconnected. We are working to develop comprehensive assurance frameworks that address potential vulnerabilities and ensure the integrity of both physical and digital components of rail systems.

Where in the lifecycle of a rolling stock or locomotive project does your company bring the most value, and why?

Walter Wagner: Endego adds value throughout the entire lifecycle, from initial design and simulation to final production and modernisation. Our integrated approach ensures that all aspects of the project are aligned, reducing risks and enhancing efficiency.

Jan Scheepers: Ricardo’s strength lies in the early stages and certification of the project lifecycle, where we ensure that designs meet safety and performance standards. Our involvement from the outset helps to identify and mitigate potential issues before they arise.

The pace of development is accelerating. Which technologies or trends (e.g., hydrogen and battery propulsion, digital twins, or automation) do you see as most impactful for the future of rail?

Walter Wagner: Hydrogen and battery propulsion is a game-changer, offering a sustainable alternative to traditional diesel engines. Digital twins are also revolutionising maintenance and operations by providing real-time insights into system performance. Automation is enhancing efficiency and safety, paving the way for more intelligent rail networks.

Jan Scheepers: I concur with Walter. The integration of these technologies is transforming rail systems, making them more sustainable, efficient, and resilient. At Ricardo, we are focusing on developing requirements and assurance processes that support the safe and effective implementation of these innovations.

Are there any upcoming developments you’re especially excited or perhaps concerned about from a technical or business standpoint?

Walter Wagner: I’m excited about the potential of autonomous trains and their ability to optimise operations and reduce human error. However, this also presents challenges in terms of safety and regulatory compliance, which we are actively addressing.

Jan Scheepers: The development of interoperable systems, which includes ERTMS and sustainable deployment across different regions, is an exciting prospect, facilitating seamless travel and operations. The challenge lies in ensuring that these systems meet diverse regulatory requirements and maintain high safety standards.

 And in your view, are your companies ready to meet those developments head-on?

Walter Wagner: Yes, Endego is committed to staying at the forefront of technological advancements. We are continuously investing in research and development to ensure that we can meet the evolving needs of the rail industry.

Jan Scheepers: Ricardo is equally prepared. Our focus on innovation and safety assurance positions us well to support the industry as it embraces new technologies and methodologies.

We know that each, Ricardo and Endego, bring distinct technical strengths, but together, you offer a powerful, end-to-end solution. How do your companies complement each other in practice?

Walter Wagner: We complement each other by offering a complete range of services. Endego brings extensive expertise in rolling stock design, simulation, and modernisation. Our focus is on the technical side of engineering—developing innovative designs, optimising performance, and ensuring sustainability. Ricardo, on the other hand, excels in system assurance, validation, and certification, providing deep expertise in ensuring that these designs meet regulatory standards and performance requirements. By combining these strengths, we can offer our clients a seamless solution that covers the entire lifecycle of a project, from initial design to final certification and implementation.

Jan Scheppers: Exactly. While Endego focuses on the design and simulation aspects, we at Ricardo ensure that these designs are thoroughly specified, validated, certified, and comply with all necessary standards. Our collaboration ensures that not only are we providing cutting-edge designs, but we’re also ensuring safety, regulatory compliance, and performance efficiency. It’s this blend of creativity and rigour that makes our partnership so effective. Clients benefit from a comprehensive approach that guarantees both innovative design and rigorous assurance.

What makes the collaboration between your teams work so well, especially in large or complex rolling stock projects?

Walter Wagner: Our collaboration thrives on clear communication and a shared commitment to quality and innovation. We have established strong lines of communication between our teams, which helps in overcoming any technical challenges that arise. With large or complex projects, this seamless exchange of information and regular feedback loops are essential. We respect each other’s expertise and collaborate closely to ensure that every stage of the project aligns perfectly—whether it’s design, validation, or certification. We also adapt to each project’s unique requirements, which is crucial for meeting the diverse needs of our clients.

Jan Scheppers: The success of our collaboration is rooted in mutual respect and understanding of our distinct areas of expertise. In large projects, where the scope can be overwhelming, both companies must be aligned from the start. This allows us to tackle each aspect—design, safety, compliance, and operational performance—at the right time and with precision. Our teams can collaborate efficiently because we share a common goal: delivering the best possible solution to our clients. Furthermore, both of our organisations value innovation and reliability, which keeps us moving forward even with the most complex challenges.

 Can you walk us through a typical project flow where your combined capabilities made a clear difference for the client?

Walter Wagner: Certainly, let’s take a typical rolling stock modernisation project as an example. The first phase would begin with Endego’s design team working closely with the client to assess their needs and start conceptualising the design. We use advanced simulation tools to ensure that the designs are not only innovative but also functional and efficient. Once the design is set, our team hands over the project to Ricardo for validation and certification. Ricardo’s experts then conduct rigorous testing to ensure the design meets all safety standards and regulatory requirements. Finally, the validated design goes back to Endego for any adjustments or improvements. This end-to-end flow ensures that our clients get a product that is both cutting-edge and fully compliant.

Jan Scheppers: That’s exactly how it works. In this flow, our team adds value by ensuring at critical stages of the design process. Our involvement in the early phases ensures that we identify potential issues before they become problems, which helps in reducing the overall time to market. We don’t just verify the final product; we ensure that it meets performance and safety expectations at every stage of development. It’s a collaborative approach that reduces risk and leads to more successful outcomes for our clients.

Endego takes over where Ricardo stops, where the engineering starts and Ricardo will take over where Endego stops their engineering work with systems assurance and certification.

From a client’s perspective, what are the key advantages of choosing Ricardo and Endego as an integrated solution provider?

Walter Wagner: From a client’s perspective, the most significant advantage is that they get an integrated solution that covers all the critical aspects of a project, from design and simulation to certification and system validation. They don’t need to engage multiple vendors or manage complicated coordination between different service providers. We offer a single point of contact for all engineering needs, which streamlines the process and reduces the chances of miscommunication or delays. Furthermore, our combined expertise allows us to approach each project with a comprehensive view, ensuring that both innovation and compliance are prioritised.

Jan Scheppers: Exactly, and another key advantage is the ability to deliver faster, more reliable outcomes. By combining our strengths, we ensure that all technical and regulatory challenges are tackled simultaneously, reducing the overall project timeline. For clients, this means fewer delays, fewer cost overruns, and a greater level of certainty throughout the process. It also means we can respond quickly to any unforeseen challenges, adjusting our approach as needed, all while keeping the project on track. Clients benefit from a solution that’s not only technically advanced but also highly efficient.

Finally, what message would you like to leave with rail manufacturers, operators, or suppliers who are navigating major technical or strategic decisions today?

Walter Wagner: The railway industry is evolving rapidly, and the challenges are significant, from sustainability to digitalisation. My advice would be to embrace innovation while ensuring that safety and compliance remain a priority. Collaboration is key in this journey, and working with companies that offer integrated solutions can make all the difference. Endego is here to help guide you through the complexity of modern rail engineering, providing cutting-edge design and simulation expertise to create the best solutions for your needs.

Jan Scheppers: I would echo Walter’s message. As rail systems become more complex, it’s crucial to have a partner who can provide both technical expertise and regulatory assurance. Embracing new technologies is essential, but it must be done with a clear understanding of how these innovations impact safety and performance. At Ricardo, we are committed to ensuring that the highest standards of validation and certification are met, no matter how advanced the project. By working together, we can help rail manufacturers, operators, and suppliers make informed, future-proof decisions.

Thank you both for sharing your insights today. It’s clear that when companies like Ricardo and Endego join forces, the rail industry benefits from more innovative solutions, faster delivery, and stronger assurance.

To learn more about our integrated services or to start a conversation, visit www.ricardo.com and www.endego.com.

But how are train interiors designed today? Ergonomics, travel comfort, and accessibility are now baseline requirements—not differentiators. Rolling stock manufacturers must also comply with stringent regulations, diverse operator expectations, and strict time and cost constraints. 

This article covers: 

• the key stages in the interior design process for modern passenger trains, 
• applicable norms and technical standards for interior components, 
• how digital simulations support design and validation, 
• challenges faced by OEMs and interior component suppliers, 
• trends shaping the trains of the future, 
• how to align passenger expectations with regulatory and technical requirements. 

Passenger experience as a design foundation 

In rail transport, “user experience” goes beyond a comfortable seat—it encompasses the entire journey from boarding to disembarking. Travel comfort is largely shaped by interior ergonomics: optimized seat profiles, clear space for movement and luggage, and intuitive access to information. Acoustic design is equally crucial—noise-dampening materials and vibration-reducing solutions significantly improve travel conditions, enabling passengers to work or relax. 

Modern LED lighting enhances the onboard atmosphere and contributes to user safety. Accessibility is also fundamental: wide aisles, dedicated spaces for passengers with reduced mobility (PRMs), and intuitive signage are key elements. A holistic approach is essential to create environments that meet both passenger expectations and operator requirements. 

Interior design standards for Rolling Stock 

Train interior design must fully adhere to a range of technical standards, ensuring both safety and passenger comfort. Among the most important are the TSI PRM (Technical Specifications for Interoperability – Persons with Reduced Mobility), which define requirements for accessibility – including minimum aisle widths, button placements, and designated wheelchair spaces equipped with proper fittings. 

EN 45545 is the European standard regulating fire safety for materials and components used in train interiors. Compliance requires that cabin elements such as seats, wall panels, and enclosures pass strict tests for flammability, smoke emissions, and toxicity. 

Additional standards address acoustic and climate-related parameters—including maximum noise levels, thermal insulation effectiveness, and HVAC system performance. These factors directly impact both comfort and energy efficiency. 

Examples of critical technical requirements include: 

• Minimum clearances for wheelchair spaces, 
• Fire resistance of interior materials in line with EN 45545, 
• Interior noise levels not exceeding specified dB(A) thresholds, 
• Temperature and ventilation control in passenger compartments, 
• Use of both visual and auditory passenger information systems. 

Meeting these standards requires certified documentation. Only then can rolling stock be approved for market operation and confirmed as safe and functional. 

The Interior design process 

Designing a modern train interior requires the careful integration of aesthetics, technical requirements, and onboard systems. The process typically includes: 

• Needs Analysis – identifying requirements for passenger comfort, flow, accessibility, and route specifics (e.g., regional vs. long-distance lines), 
• Concept Design – creating layout variants with ergonomic considerations and flexibility for diverse passenger needs, 
• Virtual Prototyping & Simulation – developing and computationally verifying detailed 3D models, including integrated systems, 
• Design Validation – optimizing and verifying compliance with technical and functional specifications before building physical prototypes. 

System integration is a vital part of this process and includes: 

• HVAC systems, 
• Passenger information and multimedia systems, 
• Wi-Fi networks, 
• Safety and surveillance systems. 

All installations must fit into confined spaces, function seamlessly together, and meet fire safety and acoustic standards. 

To reduce weight and improve energy efficiency, engineers use lightweight materials and composite structures that minimize axle loads, lower energy consumption, reduce operating costs, and simplify assembly and maintenance. 

Digital simulations and virtual validation 

Advanced engineering simulations are foundational to the modern design process, enabling comprehensive validation before any physical prototypes are built. 

Common simulation methods include: 

• CFD (Computational Fluid Dynamics) – used to analyze airflow and temperature distribution within the cabin, optimizing HVAC system performance and thermal comfort, 
• FEA (Finite Element Analysis) – to assess the structural integrity of seats, panel fastenings, ceilings, and sanitary components, 
• Passenger Flow Simulation – models boarding and alighting dynamics, evaluates internal traffic flow and evacuation safety, 
• Acoustic Simulations – predict noise sources, vibration levels, and sound propagation, aiding in effective noise control design. 

Business benefits of simulation-based design include: 

• Shorter development cycles and faster time-to-market, 
• Fewer costly physical prototypes, 
• Early detection of design flaws, 
• Easier certification preparation with simulation-based standard compliance. 

With CAE-supported virtual validation: rolling stock manufacturers can reduce risk, control development costs, and ensure high-quality implementation across platforms. 

Key challenges for interior component manufacturers 

Designing and manufacturing modern train interiors comes with several technical and organizational challenges. 

One major issue is integrating modern subsystems into existing rolling stock platforms—many of which are based on designs from previous decades. This means retrofitting passenger information systems, Wi-Fi, and HVAC units into limited mounting space and legacy electrical infrastructure. (See also our article “Rolling Stock Modernization – Giving Old Trains a New Life.” –

Manufacturers must also accommodate varied operator requirements—from interior finish preferences and national/regional standards to accessibility rules. In addition, they often face tight delivery schedules and cost constraints, demanding a flexible development and production approach. 

Another critical challenge is managing technical documentation and certification. Each component must be verified in line with TSI PRM, EN 45545, and local safety regulations, involving extensive documentation and testing. 

For more insights into platform-level constraints, see our article: “Challenges in Rail Vehicle Design.”

Interior design trends in rail transport 

The focus of modern rail interior design is increasingly on creating exceptional passenger experiences and supporting sustainable development. Key trends include: 

• Personalized Spaces – travelers expect tailored environments. In response, manufacturers are developing dedicated zones, such as workspaces with USB ports and tables, family compartments, and quiet zones. These enhancements boost passenger comfort and help operators differentiate their services. 
• Smart Technologies & Connectivity – real-time passenger information, onboard Wi-Fi, and multimedia systems are becoming standard. These tools support work, entertainment, and travel planning. 
• Sustainability & Recycled Materials – growing environmental awareness drives the use of lightweight composites, recycled materials, and solutions that reduce energy consumption and noise emissions. 
• Inclusive Design – wide aisles, dedicated wheelchair areas, high-contrast signage, and ergonomic handrails create accessible interiors for passengers with reduced mobility, seniors, and families. Inclusive design enhances travel comfort and ensures compliance with TSI PRM standards. 

Merging expectations with technology 

Designing modern train interiors is where ergonomics, smart technology, stringent safety regulations, and rising passenger expectations converge. A comprehensive approach—from user needs analysis to digital simulations and integrated system certification—enables the creation of welcoming interiors that help operators stand out in the transport market. 

Explore how Endego designs the rail systems of the future and discover our services in rolling stock design and development. We support OEMs and railway operators in transforming user requirements into tangible, optimized solutions. 

Contact us to discuss your project. 

The global wiring harness market is expanding rapidly to support rising vehicle electrification and digitalisation. In 2025, the market is estimated to be between USD 67 billion and USD 90 billion, driven by advanced driver-assistance systems (ADAS), infotainment, and high-voltage electric vehicle systems. Analysts expect it to double by 2035, growing at a compound annual growth rate (CAGR) of 6 – 7%. 

Asia-Pacific leads the deployment of harness systems, representing nearly 48% of the market in 2024, while the HVAC and high-voltage segments are growing fastest, with a CAGR of 11%, reflecting their importance in EV architectures. 

Engineering challenges behind the scenes 

Harness design is far from simple. Engineers must balance: 

• Electrical performance: Supporting high-voltage power lines and high-speed data buses,
• Mechanical reliability: Withstanding thermal and vibrational stresses, 
• Manufacturability & modularity: Ensuring cost-effective production in lean and automated workflows.

AI is making its mark – now helping optimise harness routing, reduce weight, and automate connector placement. Robotics and vision systems are even planning for automated connector mating, a breakthrough in reducing manual assembly errors. 

Endego’s capabilities in Wiring Harness engineering  

From the definition provided on our Wiring Harness Competence page, Endego brings deep, real-world expertise in designing and implementing wiring harness systems: 

• Comprehensive development of wiring harness architecture – from concept through to production readiness,
• Detailed electrical and mechanical design, including shielding, connector placement, and stress resistance,
• Support for high-voltage and data-critical systems, ensuring reliability under real-world conditions,
• Seamless integration into vehicle layouts, considering assembly constraints, serviceability, and mass optimisation.

These services are offered through flexible delivery models, including Talent-as-a-Service (TaaS), Solution Delivery, and Build-Operate-Transfer (BOT), ensuring alignment with client team structures, development timelines, and scalability needs. 

Why Wiring Harnesses are central to Next-Gen vehicles 

1. Safety & compliance: High-voltage events in EVs carry additional regulatory scrutiny, especially for insulation and fire-retardant design.
2. Vehicle performance: Automotive innovations – like 48-volt systems, zonal architectures, and high-speed data – depend on robust, precise wiring.
3. Manufacturability: As Industry 4.0 takes hold, harnesses must support automated installation and quality traceability.
4. Cost & weight optimisation: Innovative routing, modular design, and material selection enhance efficiency and reduce waste.

The wiring harness is the invisible backbone of every vehicle’s electrical system. As software-defined architectures, electrification, and connectivity transform mobility, wiring design is gaining the engineering spotlight. 

Endego’s blend of deep architecture skills, engineering precision, and development flexibility empowers OEMs and Tier-1 suppliers to deliver harness systems that meet tomorrow’s performance, safety, and cost requirements. 

Sources: 

• Future Market Insights – Automotive Wiring Harness Market Outlook (2025, CAGR 6.4%) 
  https://www.futuremarketinsights.com/reports/global-automotive-wiring-harness-market 
• GlobeNewswire – Automotive Wiring Harness Market to Reach USD 125.3B by 2035 
  https://www.globenewswire.com/news-release/2025/02/17/3027180/0/en/Exploring-the-Growth-of-the-Automotive-Wiring-Harness-Market-USD-125-3-Billion-by-2035-Future-Market-Insights-Inc.html 
• Precedence Research – Automotive Wiring Harness Market Size 2025–2034 
  https://www.precedenceresearch.com/automotive-wiring-harness-market 
• ArXiv – AI-based Framework for Connector Mating in Robotic Harness Installation 
  https://arxiv.org/abs/2503.09409 

In this article, we discuss: 

• what is rolling stock modernisation,
• why modernisation may be a better alternative to purchasing a new vehicle, 
• what are the benefits of rolling stock modernisation, 
• what are the challenges associated with modernisation, 
• how does the train modernisation process work, 
• current trends in rolling stock modernisation. 

What is rolling stock modernisation? 

Rolling stock modernisation is more than just repair – it is a comprehensive overhaul of a railway vehicle that goes beyond mere restoration to improve and expand its functionality, safety, comfort and compliance with current standards. It includes, among other things, the reconstruction of the vehicle’s front end, the modernisation of the driver’s cab, new cladding materials (e.g. aluminium, composites), as well as changes to the interior – from the seating layout to air conditioning, passenger information and Wi-Fi systems. The drive, electrical and safety systems are also often upgraded to ensure that the vehicle meets the most important current TSI, EN and fire safety standards. The result? Longer service life, better energy efficiency and rolling stock adapted to modern expectations. 

Modernisation instead of purchase 

Rolling stock modernisation is a viable alternative to purchasing new vehicles. It allows existing units to be upgraded at 30% to 50% of the price of a new train, reducing the delivery time to about a dozen months. This is particularly cost-effective when the basic structure of the vehicle, i.e. the frame, load-bearing elements and mechanical components, remains in good condition. The modernisation process usually covers areas such as the drive system, driver’s cab, passenger interior, on-board installations and safety systems. It is estimated that it can extend the service life of a vehicle by up to 15 to 20 years.

The benefits of rolling stock modernisation are multifaceted. They include lower investment costs, simplified vehicle approval, improved energy efficiency (e.g. thanks to new drives and LED lighting) and significantly increased passenger comfort. What is more, modernised rolling stock also improves safety. This is due to, among other things, the installation of advanced monitoring systems, better protection of the driver’s cab in the event of collisions and compliance with current fire safety requirements. 

Technical challenges in rolling stock modernisation 

Rolling stock modernisation is not just about changing the appearance or installing new systems. It is also a complex technical process that requires the precise adaptation of new solutions to the existing vehicle structure. The key challenges of rolling stock modernisation are: 

• adapting the new front end to the existing structure – it must ensure full structural and aerodynamic compatibility with the rest of the vehicle, while meeting collision standards (e.g. EN 15227) and allowing for the installation of modern systems (cameras, sensors, radars). 
• integrating new systems with existing infrastructure – ETCS, monitoring, HVAC and passenger information systems must be integrated into often outdated electrical and mechanical systems without compromising their functionality. 
• design constraints – factors such as available technical space, total vehicle weight, axle load distribution and the geometric parameters of the bogie, base frame and car body must be taken into account.
• compliance with standards and certification – each modernised vehicle must comply with a number of current regulations, including TSI LOC&PAS and PRM, as well as EN standards for fire safety and electrical installations. 
• assessment of material fatigue – before modernisation, a thorough analysis of the technical condition of the structure is necessary, including non-destructive testing. This allows the economic and technical feasibility of modernisation to be assessed. 

Modernisation offers great opportunities, but it has its own specific characteristics and requires precision, experience and a skilful combination of modernity and the limitations of the existing platform. 

How does the modernisation process work? 

Rolling stock modernisation is a multi-stage process that requires precise planning, engineering know-how and close cooperation between design, technology and production teams. It consists of several stages: 

1. technical audit – a thorough analysis of the technical condition of the vehicle: from the base frame and load-bearing elements, through the bogies, to the electrical installations and cabin equipment. At this stage, components that need to be replaced, repaired or adapted to standards are identified.
2. design and computational simulations – a key stage of any modernisation. The process begins with applying the planned changes to a 3D model, followed by virtual CAE validation, which includes, among other things, strength analyses (FEM) and crash tests in accordance with EN 15227. Simulations allow us to assess the rigidity of the structure, the distribution of crumple zones and the level of safety in the driver’s cab even before production begins. The course of this process can be seen in our case study (example project): ‘Optimisation of the structure of the type 20D locomotive’. 
3. production and prefabrication of components – new components, such as the vehicle front, side wall elements and interior modules, are manufactured in accordance with technical documentation at a modernisation plant. Functional and safety tests are also carried out there. 
4. assembly, testing and certification – Prefabrication is followed by component assembly and system integration. The final stage consists of operational tests, approvals and acceptance by the customer.

Trends in modernisation 

The modernisation of rolling stock is a dynamic process that evolves with technological developments and growing market requirements. We are currently observing several key trends: 

• hybrid modernisation – classic bodywork supplemented with a lightweight composite vehicle front. This solution improves aerodynamics, safety and aesthetics while maintaining the original’s robustness. This is clearly visible in our project ‘Modernisation of the front structure of the ED72 electric multiple unit’. 
• smart systems – advanced monitoring and management systems are becoming standard. The installation of external cameras, sensors, radars and intelligent systems allows for better control of the vehicle’s surroundings, obstacle detection and even assistance to the driver with automatic braking systems. This is also an important step towards full integration with traffic control systems such as ETCS. 
• recycling and reuse of materials – sustainable development activities are gaining importance. Recycled materials are increasingly being used in the modernisation process, as well as technologies that enable the recovery and reuse of large rolling stock components, such as base frame. This not only reduces costs, but also reduces the carbon footprint of vehicle production and modernisation.
• environmental and social requirements – vehicles must be accessible to people with reduced mobility, which requires, among other things, special ramps, wider aisles and interior amenities. In addition, improving acoustic comfort is important – quieter interiors improve passenger comfort, and better thermal insulation increases the comfort and energy efficiency of the vehicle, reducing energy consumption for heating and air conditioning. 

Development through modernisation 

Today, rolling stock modernisation is not only a way to extend the life of vehicles, but above all a tool for building modern, safe and competitive rail transport in a shorter time. It allows for the incorporation of current technical standards, increased passenger comfort, reduced energy consumption and shorter vehicle implementation times, while significantly reducing costs compared to the purchase of new units. 

Modernisation is therefore not just a technical refresh of the vehicle, but a well-thought-out, strategic investment that allows for a flexible and economical response to market needs and improves the image of the carrier without the need to replace the entire fleet. 

At Endego, we support rolling stock manufacturers in a wide range of rail vehicle design and optimisation services, from the front-end modernisation and strength analyses to the integration of modern systems and preparation of certification documentation. 

Contact us to discuss your project. 

Contemporary car bumpers must meet strict approval standards, be adapted for the installation of sensors and cameras, and at the same time fit in with the dynamic lines of the bodywork. They are increasingly made of modern composite materials that combine lightness with high strength. By influencing airflow management, the bumper also has a significant impact on fuel consumption and vehicle performance.

In this article, we will discuss:

• what exactly a bumper is in an engineering context,
• what functions it performs,
• what materials are used in its production,
• how it affects the aerodynamics of a vehicle,
• what the car bumper design process looks like – from the concept phase to production.

Car bumper – from a metal bar to an intelligent safety system

The first bumper was installed in 1897 by the Czech company Nesselsdorfer – it was a steel bar, mainly serving a decorative and, to a minimal extent, protective function. In the 1920s, chrome bumpers appeared, combining aesthetic and protective functionality.

The breakthrough came in the 1960s and 1970s, with the first safety regulations. In 1968, General Motors used a bumper made of ‘Endura’ plastic in its Pontiac GTO model, capable of absorbing impacts at low speeds. Similar solutions were later introduced in the Plymouth Barracuda and Renault 5 models.

Modern bumpers are made from advanced composite materials that integrate safety systems. They combine lightness with high strength and are designed to protect both passengers and pedestrians.

Car bumper – what are its functions?

Although for many years the bumper was seen mainly as a protective element – designed to minimise the effects of minor collisions and protect the bodywork – today its role is much more complex. A modern car bumper is a component of strategic importance that must combine functionality, safety, aesthetics and advanced technological integration.

Key functions of a modern car bumper:

• passive and active safety – the bumper is designed to absorb energy during collisions, thereby minimising vehicle damage and reducing the risk of injury to passengers. New designs also take into account pedestrian protection (following international pedestrian safety standards), which influences their shape and material.
• integration with ADAS systems – bumpers must be designed to work with advanced driver assistance systems (ADAS), such as radars, parking sensors, cameras, and lidars. This requires precise design and material parameters that do not interfere with the operation of these devices.
• aesthetics and brand identity – bumpers directly affect the appearance of the front and rear of the vehicle. Their shape, lines and finish are important design elements, often reflecting the manufacturer’s distinctive style.
• aerodynamics – a properly designed bumper can significantly reduce air resistance, improving fuel efficiency and driving stability at higher speeds.
• protection of mechanical components – the bumper protects delicate vehicle components such as the radiator, headlights, exhaust system, and suspension parts from damage caused by impacts, water spray, debris, or road gravel.

As a result, bumper design is an art of compromise between technical requirements, safety standards, manufacturing constraints and aesthetics. Today, a bumper is not just a ‘buffer’. It is now an intelligent structural component that performs many key functions in modern cars.

What materials are used to manufacture bumpers?

Steel bumpers, although very durable, were heavy and rigid, which meant poorer impact energy absorption at low speeds and higher fuel consumption. Aluminium bumpers, on the other hand, although lighter, were more expensive to manufacture and more difficult to process. With the development of technology and the growing emphasis on fuel economy, lightness and safety, manufacturers began to use plastics with precisely selected mechanical properties.

Today, car bumpers are most often made of materials such as:

• PP (polypropylene) – the most popular material in bumper production. It is lightweight, inexpensive, flexible and absorbs impact energy well. In addition, it is easily recyclable.
• ABS (acrylonitrile butadiene styrene terpolymer) – a material that is stiffer than PP, but also impact resistant. It is ideal for more complex bumper designs that require a precise finish.
• PC/ABS – a mixture of polycarbonate and ABS, offering increased resistance to temperature and mechanical damage. Used especially in vehicles that must meet strict safety standards.
• glass or carbon fibre composites – lightweight, rigid and very durable. Mainly used in sports, luxury and racing cars, where every gram counts and maximum aerodynamics is essential.
• recycled plastics – bumpers are increasingly being manufactured partly from recycled plastics, in line with the trend towards sustainable development in the automotive industry and zero waste policies.

Modern bumpers are designed to combine lightness, flexibility, aesthetics and functionality, while remaining fully compatible with safety systems (such as sensors, cameras and radars).

The impact of the bumper on vehicle aerodynamics

While it may not be immediately apparent, a car bumper has a real impact on the aerodynamics of a vehicle, i.e. how air flows over the bodywork while driving. Its role today is not limited to protection or aesthetics – it is one of the key elements influencing fuel consumption, handling stability and cooling of mechanical systems.

A well-designed bumper:

• reduces air resistance (drag coefficient), which translates into lower fuel consumption and higher energy efficiency,
• directs airflow to the radiator, supporting effective cooling of the engine or battery systems,
• reduces turbulence in the wheel arches and wheels, which improves stability and acoustics in the car interior,
• affects traction and aerodynamic downforce, which is particularly important in sports cars.

In many models, especially electric or sports cars, the bumper is integrated with additional aerodynamic elements, such as:

• grilles – often with active shutters that open only when cooling is needed and remain closed otherwise, reducing air resistance. We wrote more about car grilles in the article ‘What is a car grille and what are its functions in a vehicle?’,
• splitters – small ‘wings’ at the lower edge of the front bumper that press the front of the vehicle to the road surface, increasing vehicle stability,
• diffusers and rear spoilers – elements of the rear bumper that regulate air flow under and behind the vehicle, improving stability at higher speeds. For more information on spoilers, see the article: ‘Car spoilers – what are they, what are they for and how are they designed?’,
• air ducts and active flaps that optimise airflow while driving, depending on road conditions and driving mode.

Today, bumper aerodynamics is not only the domain of racing cars – manufacturers are also increasingly focusing on optimising the shape of the front and rear of city cars, compact cars and electric cars. This makes it possible to reduce air resistance, which directly translates into improved vehicle performance and lower fuel or energy consumption. It also improves stability and driving comfort, especially at higher speeds.

That is why modern bumper designs often include special creases, air channels or active elements that dynamically adapt to driving conditions, maximising aerodynamic efficiency.

Car bumper design – from concept to production

The bumper design process is a complex and multi-stage cycle that requires close cooperation between engineers, stylists and safety and aerodynamics specialists. Specific standards must be met at every stage so that the design complies with formal requirements as well as the expectations of the manufacturer and users.

Stages of car bumper design:

• regulatory and functional requirements analysis – taking into account approval regulations such as GTR (Global Technical Regulations), FMVSS (Federal Motor Vehicle Safety Standards) and UNECE standards. This step also defines the manufacturer’s needs and compatibility with ADAS (Advanced Driver Assistance Systems).
• initial styling and concept design – shaping the bumper to harmoniously fit the body style while meeting functional requirements.
• CFD (Computational Fluid Dynamics) simulations and tests – virtual analysis of air flow around the bumper, allowing for optimisation of aerodynamics, reduction of air resistance and improvement of cooling of key components.
• virtual crash validation – advanced computer simulations that predict the behaviour of the bumper during a collision, allowing the design and materials to be optimised before a physical prototype is created.
• material selection – selection of appropriate plastics and composites that provide the desired lightness, flexibility and damage resistance.
• physical prototyping and crash validation – construction of the first physical samples and testing them in real-life conditions to confirm the effectiveness of energy absorption and product durability.
• integration with additional component systems – installation of parking sensors, radars, cameras, tow bars and aerodynamic covers.
• mass production – usually carried out by injection moulding, often with additional finishing processes such as painting, chrome plating or soft-touch coating.

Designers must also pay attention to the ease of repair and the cost of replacing the bumper, which has a direct impact on the total cost of vehicle ownership.

The bumper – a functional component of a modern vehicle

A car bumper is much more than just a ‘buffer’ at the front and rear of a vehicle. Its design combines safety, aerodynamics and integration with electronic systems. It must effectively absorb the energy of a collision, not interfere with the operation of ADAS radars or cameras, and at the same time support airflow around the body.

In the age of electromobility and advanced driver assistance technologies, bumper design is an interdisciplinary process combining the requirements of mechanical engineering, aerodynamics, electronics and design. A well-designed bumper has a positive impact on the performance, comfort, safety and aesthetics of a vehicle.

The bumper design process is a complex undertaking, ranging from regulatory analysis and digital simulations to physical testing and production implementation. There is no room for randomness.

At Endego, we support every stage of the project – from defining objectives to production implementation. Our services include not only car body and vehicle design, but also:

• car interior and cockpit design,
• car wiring harness design,
• design of lighting and optical systems for vehicles,
• software & hardware for cars and the automotive industry,
• powertrain systems,
• computer-aided engineering simulations (CAE).

Looking for an experienced engineering partner to support your automotive development? Contact us.