Abstract: A vehicle bulb shield with material differences in configuration, thickness, strength, grade or surface coating in the leg and shield sections, manufactured from a tailor welded steel strip of different materials to obtain desired corresponding combinations of features in each component from each material. A progressive forming process is used to accommodate the different metal combinations within the tailor welded steel strip (e.g. material type and/or thickness), and thereby allow new material property configurations in the bulb shield components. A material property configured bulb shield design enables consideration of formability of material in different component sections, the rigidity of material in different component sections, and cost of different materials, in a single component design.

Abstract: The present application provides a method and system for modeling surface roughness or cosmetic appearance as the result of manufacturing process performed on metal products. The method and system include loading of the desired dimensions of a metal product to be manufactured into a computer aided design program. A computer aided design model of the metal product to be manufactured is then generated, and the predicted levels of strain associated with manufacture of the metal product are also generated. A database of the characteristics of the metal material used in the manufacturing process is also created, including a digital image, resulting from physical testing of different desired materials to form the product to be manufactured.

Abstract: A vehicle bulb shield with material differences in configuration, thickness, strength, grade or surface coating in the leg and shield sections, manufactured from a tailor welded steel strip of different materials to obtain desired corresponding combinations of features in each component from each material. A progressive forming process is used to accommodate the different metal combinations within the tailor welded steel strip (e.g. material type and/or thickness), and thereby allow new material property configurations in the bulb shield components. A material property configured bulb shield design enables consideration of formability of material in different component sections, the rigidity of material in different component sections, and cost of different materials, in a single component design.