Custom Floor Mat Design for Ford Tourneo

Overview

This project involved the development of a custom floor mat for the second row of a Ford Tourneo van, designed to improve usability and cleanliness within the vehicle interior.

Using high-accuracy 3D scanning, the full geometry of the vehicle floor was captured and used as a foundation for the design. The solution was tailored to integrate with the existing seat track system while addressing the client’s specific requirements.

Challenge

The vehicle floor included seat tracks and recessed areas that tend to trap debris and are difficult to clean using standard floor mats.

The design needed to:

• conform precisely to complex floor geometry

• accommodate seat track features

• improve ease of cleaning and maintenance

• remain suitable for manufacturing

Process

• 3D scanning of the vehicle floor

• Processing and alignment of scan data

• Reverse engineering of floor geometry

• CAD modelling of custom rubber mat

• Design optimisation for manufacturability

Result

A functional and manufacturable CAD design was delivered, providing:

• precise fitment within the vehicle interior

• improved usability and accessibility

• easier cleaning around seat track areas

The final design is ready for production and can be manufactured using appropriate materials such as rubber or flexible polymers.

Technologies Used

• 3D Scanning

• Reverse Engineering

• CAD Modelling

• Product Design