Exploring Virtual Geometry Assurance for the Nominal Buck Verification Process at Polestar

Abstract

This thesis investigates the feasibility of digitalizing the nominal buck verification process at Polestar using virtual geometry assurance software such as RD&T. The nominal buck, a physical aluminum structure representing the ideal chassis geometry, is currently employed in Polestar’s verification process to evaluate the fit and alignment of interior and exterior vehicle components. Although the process is reliable with a high accuracy when it comes to asserting the geometric state of a part, the process is costly, time-consuming, and environmentally demanding. The objective of this study is to assess whether a virtual alternative can replace or complement the physical verification approach to improve efficiency, accuracy, sustainability, costeffectiveness and flexibility. Through a combination of literature reviews, industry interviews, and a detailed case study, the project explores the capabilities of RD&T for simulating geometric variation and part assembly. The digital method involves 3D scanning of physical parts, creating virtual fixtures, and applying statistical variation analyses to predict assembly behavior and compliance with tolerances. The research also includes a comparative analysis between the physical and digital approaches, highlighting advantages such as reduced lead times, lower material consumption, increased process flexibility, and enhanced data traceability. The results suggest that a virtual verification process using RD&T can significantly improve the robustness and efficiency of the geometry assurance processes at Polestar, with additional sustainability benefits including waste reduction and streamlined global collaboration. However, challenges such as software limitations, implementation complexity, and required changes in workflow and skill sets must be addressed. This thesis contributes to the advancement of digital manufacturing practices and supports Polestar’s strategic sustainability and innovation goals