*Subject to University Approval

In a rapidly evolving automotive sector, virtual prototyping for vehicle structures is an essential part of the development process of innovative vehicle designs. This course empowers students with the advanced skills and tools needed to reshape vehicle design, focusing on advanced simulation, passive safety and material characterisation. For CAE engineers and their teams, this knowledge is crucial for optimising design processes, minimising the need for physical prototypes, and delivering reliable, data-driven solutions that accelerate development and improve vehicle performance from road vehicles to racing cars.

The MSc in Virtual Prototyping for Vehicle Structures has been developed to provide the Automotive and Motorsport industry with high calibre stress analysts that are equipped with the necessary skills to meet the demands of the structures and CAE department.

Through hands-on experience with advanced simulation tools and industry-leading techniques, students will be inspired to push the boundaries of innovation to contribute to the development of smarter, safer and more efficient vehicles.

The balance between lab experience at the Cranfield Impact Centre and exposure to advanced simulation techniques will provide a comprehensive understanding of both theoretical and practical aspects to analyse prototypes in a virtual environment and refine their concepts through testing.

Overview

  • Start dateOctober
  • DurationOne year full-time
  • DeliveryTaught modules 40%, Group project 20%, Individual research project 40%
  • QualificationMSc
  • Study typeFull-time
  • CampusCranfield campus

Who is it for?

The MSc in Virtual Prototyping for Vehicle Structures is suitable for graduates in engineering, physics or mathematics, and will prepare you for a career in this exciting field, from chassis, suspension design to crash analysis and NVH.

Why this course?

Students taking the Virtual Prototyping for Vehicle Structures course will benefit from ÂãÁÄÖ±²¥'s world-class facilities and expertise, particularly the unique capabilities of the Cranfield Impact Centre (CIC). The CIC is one of the most advanced testing facilities of its kind in the world, offering exclusive access to cutting-edge equipment for crash testing and vehicle safety analysis. This, combined with the advanced mechanical labs at ÂãÁÄÖ±²¥, ensures that students receive hands-on experience with the latest technologies in vehicle design and testing.

This hands-on experience, combined with theoretical learning, gives students a unique perspective on how advanced simulation tools are used to optimise vehicle performance, reduce development time, and improve safety and sustainability in the design of automotive and motorsport structures.

Informed by Industry

The MSc in Virtual Prototyping for Vehicle Structures is directed by an Industrial Advisory Panel comprising senior engineers from the automotive and motorsport sector working in CAE and structures departments. This maintains course relevancy and ensures that graduates are equipped with the skills and knowledge required by leading employers to join their CAE and structural design team.

You will have the opportunity to attend classes from academics at ÂãÁÄÖ±²¥ and meet with key practitioners from leading automotive and motorsport companies as they offer lectures and seminars.

You will also present your work as part of selected modules and the group design project to gain insightful feedback and engagement from leading figures in the field of advanced structural simulation.

Course details

This course comprises eight compulsory taught modules that are assessed via a combination of written exams and individual coursework assignments, a group project and an individual research project.

Course delivery

Taught modules 40%, Group project 20%, Individual research project 40%

Group project

You will undertake a substantial group project between October and March, which focuses on designing and optimising a particular vehicle system/assembly. This is designed to prepare you for the project-based working environment within the majority of the automotive industry.

As a group, you will be required to present your findings, market the product and demonstrate technical expertise in the form of a written submission and a presentation to the Industrial Advisory Board, academic staff and fellow students. This presentation provides the opportunity to develop presentation skills and effectively handle questions about complex issues in a professional manner.

Individual project

The individual research project is the largest single component of the course taking place between April and August. It allows you to develop specialist skills in an area of your choice by taking the theory from the taught modules and joining it with practical application, usually involving a design feasibility assessment, systems analysis or facility development. Most of the projects are initiated by industrial contacts or associated with current research programmes.

In recent years, some industry sponsors have given students the opportunity to be based on site. Thesis topics will often become the basis of an employment opportunity or PhD research topic.

Modules

Keeping our courses up-to-date and current requires constant innovation and change. The modules we offer reflect the needs of business and industry and the research interests of our staff and, as a result, may change or be withdrawn due to research developments, legislation changes or for a variety of other reasons. Changes may also be designed to improve the student learning experience or to respond to feedback from students, external examiners, accreditation bodies and industrial advisory panels.

To give you a taster, we have listed the compulsory and elective (where applicable) modules which are currently affiliated with this course. All modules are indicative only, and may be subject to change for your year of entry.


Course modules

Compulsory modules
All the modules in the following list need to be taken as part of this course.

Automotive Engineering Induction

Aim
    To introduce the programme and the courses and the facilities available at Cranfield.
Syllabus
    • Team working
    • Project management
    • Various interpersonal skills: report writing and presentation skills 
    • Various MS Office training packages
    • Library sessions with the Information Team covering qualitative information, referencing, ethics and plagiarism.
    • Careers sessions including CV writing, preparation for interviews and assessment centres, interview techniques
Intended learning outcomes

On successful completion of this module you will be able to:

  1. Have an appreciation of the Automotive Engineering Masters programme and course philosophy, structure, content, teaching methods, staff and administration.
  2. Be familiar with key facilities (internal and external to Cranfield) and resources such as the library, computer network and Careers Service.
  3. Have experienced team building and other interpersonal skills including written and verbal communication skills.
  4. Appreciate the importance of time/project management and health and safety throughout the study.
  5. Appreciation of the fundamentals of Engineering Ethics

Vehicle Design, Propulsion and Performance

Aim
    • Provide deep understanding of vehicle propulsion options and driveline.
    • Establish approaches and procedures to analysing and predicting vehicle performance.
    • Provide a framework for the appreciation of the interdependency of vehicle systems.
    • Critically evaluate the integration of different alternative powertrain options and be able to select appropriate solutions within legislation framework.
    • Evaluate vehicle emissions and control systems to identify appropriate solutions.
Syllabus

    Basic vehicle characteristics: Vehicle concepts, centre of gravity position, static and dynamic loads and weight distributions, front, rear and all wheel drive. Adhesion coefficient and influencing factors. Traction, braking and resistance to motion.

    Fuel consumption: Engine characteristics & fuel maps. Determination of fuel consumption. Energy aspects. Legislative Drive Cycles.

    Off-Road: Introduction to off road vehicle design characteristics.

    Autonomy: Review of the current technologies surrounding Vehicle Autonomous Driving.

    Braking performance: Influence of resistances and inertia. Brake force distribution. ECE 13 legislation. Calculation of required braking characteristics. Stopping distance.

    Safety: Principles of passenger restraints, elastic/plastic restraints, energy dissipation, rebound energy (whiplash). Vehicle restraint systems and safety features. Hybrid and electric vehicle safety considerations.

    Legislation: Introduction to regulations, European directories, USA federal motor vehicle safety standards. Understanding the influence of relevant legislation on vehicle systems design.

    Driveline components: Driveline components: Friction clutches, Final drives, Differentials including e-Diff

    Manual & automatic transmissions: Description of gearbox layout and gear change mechanisms.

    Hybrid and electric vehicles: Basic definitions, HEV and EV architectures, advantages and disadvantages. Electrical and mechanical energy storage technologies including battery management considerations.

    Brakes and braking systems: Disc and drum brakes, braking systems – design, dimensioning and evaluation. Materials, manufacturing methods and testing.

    Vehicle refinement: Basic details of noise vibration and harshness and attributes for Driveline refinement.

Intended learning outcomes On successful completion of this module you should be able to:
1. Interpret and apply legislative requirements in generating vehicle concepts and designs.
2. Predict resistances to motion, determine powertrain system characteristics, calculate vehicle performance (max. speed, acceleration, gradient, fuel economy etc).
3. Understand vehicle concepts for propulsion driveline systems and components; optimise vehicle performance characteristics for the selected criteria / benchmarks.
4. Understand rotating component tribology in the context of vehicle efficiency.
5. Assess and critically evaluate vehicle systems and interdependency including vehicle design and ride quality.

Experimental Mechanics

Aim

    The aims of this module are to introduce the following elements:

    • Experimental techniques for analysis and characterization of various engineering materials.

    • Full-field, non-contact optical methods (including photoelasticity) for deformation and strain measurements.

    The module offers combination of fundamental concepts lectures, engineering theories, lab exercises and tutorials.

Syllabus
    Mechanical Testing Methods: point measurements - theory, installation technique and practice; flexure tests (beam bending); tensile test - evaluation of shear modulus, advanced characterisation techniques. Optical full field methods: photoelasticity; interferometry; digital image correlation, thermography, high strain rate testing, joints testing for opening modes characterisation, fatigue crack growth and fracture toughness, non-linear elasticity and static vs dynamic stiffness.
Intended learning outcomes

On successful completion of this module you should be able to:

1. Select and apply specific types of experiments to characterise materials/components at the appropriate level of rigour.

2. Understand the relative (dis)advantages of the available techniques and the relative costs involved in carrying out such experiments in an industrial set-up.

3. Distinguish between theoretical material parameters and experimentally evaluated material parameters and the sources of error associated with experimental techniques.

4. Identify the most appropriate experimental techniques for evaluating material response in a specific setting and for different types of materials.

Vehicle Passive Safety

Aim

    The module aims to:

    • To provide an understanding of global and local buckling and the mechanisms involved in material failure.

    • To introduce the testing methodology in crashworthiness to assess energy absorption capability of metallic and composite structures.

    • To introduce the most common features required in the simulation of crash behaviour of metallic and composite structures.

    • To review passive safety in the automotive context including current regulations and anthropomorphic test device (ATD).

    The module offers combination of fundamental concepts lectures, engineering theories, lab exercises, finite element modelling, simulations and tutorials.

Syllabus

    The module will provide knowledge in automotive crashworthiness to be able to develop crashworthy vehicles and the related simulations and testing protocols for the optimisation and validation. The interior safety and passenger injury is a key part of safety, and testing protocols with key features will be reviewed.

    Core topics:

    • Folding mechanisms and structural collapse.

    • Implicit vs explicit simulations.

    • Drop tower, sled testing and ATD.

    • Simulation of metallic and composite structures under dynamic loading.

    • Validation of numerical models.

Intended learning outcomes

On successful completion of this module you should be able to:

1. Demonstrate understanding of automotive crashworthiness and the mechanisms involved in the energy absorption systems.

2. Critically evaluate crashworthiness designs and propose experimental protocols to validate numerical models.

3. Demonstrate an understanding of the fundamentals and practical issues of crash testing and numerical simulation of dynamic phenomena.

4. Critically evaluate the interior safety of vehicles and propose measure to mitigate secondary impacts.


Vehicle Dynamics

Aim
    • To provide a fundamental understanding of vehicle dynamics as applied to wheeled vehicles.

    • To introduce students to road vehicle ride and handling, from requirements to analytical modelling and practical viewpoints.

    • To link understanding of vehicle dynamics, ride and handling to the practical implications for suspension and steering system design.

Syllabus

    The module will provide knowledge in vehicle dynamics ride and handling from subjective and objective requirements to analytical methods in developing passive ride and handling models. 

    Core topics:

    1. Vehicle ride, ride modelling and terrain modelling 
    2. Vehicle handling, steady-state and transient handling
    3. Tyre characteristics and tyre modelling 
    4. Suspension system types, typical designs and practical implications
    5. Kinematics, wheel motion control, instantaneous centres of rotation
    6. Steering system, steering kinematics and compliance.
Intended learning outcomes

On successful completion of this module you will be able to:

  1. Demonstrate understanding of vehicle dynamics models, including first principles, associated assumptions and implications to numerical simulations.
  2. Critically evaluate vehicle ride and handling performance and the role of tyre and suspension characteristics.
  3. Demonstrate an understanding of the fundamentals and practical issues of vehicle suspension and steering systems and their influence on ride and handling. 
  4. Critically evaluate suspension and steering designs, including layout, geometry and materials.
 

 

NVH and Durability

Aim
    To provide a fundamental understanding of the simulation and testing protocols to be followed to design vehicle structures. The focus is on fatigue and NVH of structural components including battery shells and powertrain components. The module offers combination of fundamental concepts lectures, engineering theories, lab exercises, finite element modelling, simulations and tutorials.
Syllabus
    The module will provide knowledge in the standards to be followed for the assessment of the durability, load spectrum, environmental conditions, testing methods, data analysis and material characterisation for fatigue and fractures. The module will also cover fundamental of modal analysis of vehicle components combining experimental techniques and numerical strategies for the modal analysis.
Intended learning outcomes

On successful completion of this module you should be able to:

1. Demonstrate understanding of durability simulation and testing.

2. Critically evaluate vehicle durability performance and the definition of boundary conditions and environmental conditions.

3. Demonstrate an understanding of NVH and implication on durability.

4. Critically evaluate material performance in the context of fatigue.

Vehicle Materials and Manufacturing

Aim
    The module aims to provide an introduction to the selection and processing, of materials for vehicle structures. Emphasis will be given to practical experience of the use of a range of materials for automotive structures focussing on manufacturing and assembly technology. The module is delivered with a combination of lectures, lab activities, and tutorials.
     
Syllabus
    • Physical properties and material models of high strength steels, stainless steels, metal matrix composites, aluminium and titanium alloys, rubbers, elastomers, plastics, honeycomb and polymer composites.
    • Manufacturing technology in the automotive industry.
    • Comparison of the most common joining techniques in the automotive industry.
    • Introduction to damage tolerance and failure mechanisms under static and dynamic load.
    • Case studies of different mechanical failures.
Intended learning outcomes

On successful completion of this module you should be able to:

  1. Evaluate material selection and performance for the manufacturing of automotive structures.
  2. Assess the design, manufacturing, assembly and testing of composite components and sub-systems.
  3. Critically evaluate innovative materials and their application.
  4. Develop an understanding of relevant failure analysis.
 

Vehicle Structures

Aim
    The module aims to provide an introduction to the design and analysis of vehicle structures. Emphasis will be given to understanding and practical experience of the use of a range of materials in car structures including design, stress analysis and performance. 

    The module offers combination of fundamental concepts lectures, engineering theories, lab exercises, finite element modelling, simulations and tutorials.
     
Syllabus
    • Review and analysis of different types of vehicle structures.
    • Load paths and interaction with other vehicle systems.
    • Structural response and stiffness analyses.
    • Design of safety and crash structures.
    • Finite element modelling and simulations.

     

Intended learning outcomes

On successful completion of this module you should be able to:

  1. Critically evaluate fundamental properties of metallic and non-metallic material for automotive structures.
  2. Design metallic and non-metallic components and sub-systems.
  3. Construct and validate finite element models.
  4. Assess active and passive automotive safety and crashworthiness.

Simulation of Composite Structures

Aim
    Provide detailed understanding and practical experience of the use of composite materials in racing car structures including materials selection, component design, manufacturing technology processing and performance.
Syllabus

    • Materials forms, performance and selection.

    • Manufacturing technology and joining techniques, including manufacturing technique training.

    • Composite structures design, analyses and optimisation techniques.

    • Design of safety structures.

    • Stress Analysis of composite Structures and simulation strategies.

Intended learning outcomes

On successful completion of this module you should be able to:

1. Apply the principles of composite material selection and performance in the design and manufacturing of structures in motorsport.

2. Evaluate upcoming materials/structural technologies and judge their possible applications.

3. Evaluate and compare the techniques used for the design, processing and assembly and testing of motorsport structural components.

4. Apply and analyse crashworthiness concepts and the influence of Motorsport regulations on the structure design.

Elective modules
One of the modules from the following list needs to be taken as part of this course.

Research Methods

Aim
    To plan, conduct and report on an original, individual programme of research within the field of Automotive Engineering/Automotive Mechatronics/Virtual Prototyping for Vehicle Structures.
Intended learning outcomes

On successful completion of this module you should be able to:

1. Identify, search for, and find research literature on a given topic.

2. Summarise, synthesise and critically evaluate literature from various sources.

3. Express technical information to various audiences as a poster and as a scientific paper.

4. Plan, implement and write up a research project.

Your career

Our postgraduate Virtual Prototyping for Vehicle Structures course provides you with the necessary skills for a career in the CAE and structures departments of automotive and motorsport companies. Cranfield’s graduates have an excellent employment record and they have secured jobs in the Vehicle Structures and Body CAE departments of leading automotive and motorsport companies.

Some of our graduates decide to continue their education through PhD studies with ÂãÁÄÖ±²¥.

Graduates of this MSc can aspire to roles such as:

Structures Analyst,
CAE Engineer,
Structural Simulation Engineer,
Vehicle Design Engineer,
Crash Safety Engineer.

 

Cranfield’s Career Service is dedicated to helping you meet your career aspirations. You will have access to career coaching and advice, CV development, interview practice, access to hundreds of available jobs via our Symplicity platform and opportunities to meet recruiting employers at our careers fairs. Our strong reputation and links with potential employers provide you with outstanding opportunities to secure interesting jobs and develop successful careers. Support continues after graduation and as a Cranfield alumnus, you have free life-long access to a range of career resources to help you continue your education and enhance your career.

How to apply

Click on the ‘Apply now’ button below to start your online application.

See our Application guide for information on our application process and entry requirements.