Marabese Research & Development

Areas and Methods of Development

Development Process:
Our proven development process allows us to have complete control over individual activities, down to the detailed definition of each component.

This method integrates with the business processes of our Partners who can easily check the progress of activities.

Product definition

Market Analysis

In this first important phase, existing models in the market are analyzed, their price positioning and what audience the product is aimed at. Engine sizes and displacements are analyzed, the types of engines (single, twin-cylinder, etc.) and what rules they have to comply with in terms of emissions; considerations are also made about the types of licenses needed to drive the products being analyzed. Last but not least, an in-depth analysis is made of what are the styling trends.

Concept of Style

With the data collected during the Market Analysis phase, we start to define the style concept by thinking from the outset about what the innovative content should be. Also at this stage, family feeling styles with previous products are defined. Again referring to the Market Analysis, the product’s price positioning and distribution areas in the market are also defined.

Style Sketches

Keeping the previous market analysis and style concept definition as guidelines, sketches of the new product are developed. For the presentation of the sketches, isometric views are required in addition to the classic orthogonal views. The sketches of the new vehicle should be differentiated by color range and contain at least an idea of the planned accessories.

Mockup

Marabese builds mockups of each product in-house on a 1:1 scale. The material used is high-density polyurethane, which allows for cleanliness and speed of execution. The mockup can be built by keeping an existing technical platform as a base or by starting from scratch by making a support jig with predefined cycling dimensions.

Mockup
Validation

At this stage, the style center gives approval to the surfaces and the overall driving ergonomics of the vehicle are confirmed. The mockup is then presented to the customer for final approval. Once approval is obtained, the mockup is “frozen” and the project is “kicked off.”

Project objectives

In parallel with the realization of the mockup starts the drafting of the design objectives. This is a document that aims to gather what will be the characteristics for each component of the vehicle; in addition, in this document the objectives to be pursued in terms of quality, comfort, performance, cost, time, etc. are defined. As with the mockup, this document, too, must first be approved internally and then signed off by the customer. The design objectives will be the guideline throughout the vehicle development.

Product development

Prestudy

At this stage the pre-study of the CAD technical and chassis base and the pre-study of the bodies, (using the mockup scan performed after customer approval) start in parallel. All technical subassemblies and types of body coupling and attachment are defined. In the prestudy phase, strategic suppliers, (chassis, bodies, engine), and the project Gantt are also defined.

Prototype 0

Using the 3D and 2D drawings made during the prestudy, construction of Prototype 0 begins. This vehicle is generally without bodywork and is used for the first phase of cycling and ergonomic development. This prototype can normally be built using components from other vehicles, the only necessity being to replicate the cycling and ergonomics geometries defined during the prestudy.

Prototype 1

The first prototype is built with prototype components using the first release CAD drawings. The bodywork made in rapid prototyping using the first release CAD drawings is assembled in this vehicle. The purpose of this prototype is to verify and validate the cycling and ergonomics tests performed with prototype 0.

Final Prototype

The final prototype is built using as many components as possible from the first mold trial. The purpose is to verify the assemblability of the components and the assembly cycles to be later transferred to production. Also with this prototype, a series of tests are done for chassis refinement and validation of all technical subassemblies of the vehicle (cooling system, fuel system, etc.).

PT Technical Preserie

Technical pre-series is the first real of assembly utlizing the production line. The vehicle components will mandatorily be components derived from final molds and final welding jigs. At this stage, all assembly and quality assurance procedures are fine-tuned and tested. From the technical pre-series vehicles, (minimum 5 to maximum 20 units), vehicles used for road durability testing, (3 vehicles for 35,000 km), and for homologation will be taken.

Commercial PC Preserie

The commercial pre-series is a kind of production dress rehearsal. Between 20 and 50 vehicles are normally produced, using components from final equipment, after any fine-tuning derived from technical pre-series testing. Vehicles produced in commercial pre-series will be saleable vehicles and normally used for press presentations and an additional 10,000 km road endurance test.

Start of production

The start of production takes place with an increasing production ramp-up over a predetermined period. With the start of production, the product audit activity also begins, which will ensure over the life of the vehicle, the quality standard stipulated in the project objectives.

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