Project:
Re-design of Aston Martin V12 Vantage Bonnet Vent
Achieving 75% reduction in part cost
Challenge
Aston Martin presented Convert Design with a challenge: redesign the V12 Vantage bonnet vent to significantly reduce cost—without compromising the brand’s signature luxury and performance.
The original vents, crafted from lacquered 2×2 twill carbon fibre, (pictured above), were key to heat management in the tightly packed engine bay. However, high material and tooling costs made them difficult to scale. The business case demanded that any new tooling be paid back within the first year. Internally, there was concern—particularly from sales—that lowering the spec could undermine customer appeal and erode revenue.
Our Role
As a trusted product development agency and industrial design consultancy in the UK, Convert Design approached the project with both engineering precision and commercial awareness.
Using Siemens NX and our deep expertise in DFM design, we delivered a manufacturing-ready solution that met cost, quality, and aesthetic requirements. Our team worked closely with Aston Martin’s design studio, management, and supplier network to ensure the end result was practical, premium, and production-ready.
What We Did
- Delivered a rapid design turnaround using high-precision CAD to meet critical business milestones.
- Designed for real-world tolerances of the existing bonnet, avoiding the need for costly rework or bonnet modification.
- Introduced a preformed strengthening bar beneath the carbon surface—improving structural fit and enabling fast, secure assembly.
- Collaborated with Aston Martin’s metrology team to ensure curvature matched the bonnet exactly.
- Brokered supplier collaboration, helping Aston Martin find a reliable overseas partner capable of premium results within budget.
- Balanced stakeholder needs—delivering a design that satisfied both engineering and sales expectations.
Results
- 75% reduction in part cost, with no loss of visual or functional quality.
- 50% of customers preferred the new mesh vent style—turning cost savings into a styling option.
- Adopted for a limited run of 15 cars, with a successful production line trial.
- Supplier approved following on-site validation and quality review.
- Flexibility retained: customers could still choose the original carbon louvre vents as an upgrade.
Outcome
Convert Design helped Aston Martin create a new, more affordable bonnet vent option—one that stayed true to brand, enhanced choice for customers, and delivered fast return on investment.
As a specialist in DFM design and manufacture-ready CAD using Siemens NX, Convert Design bridges the gap between concept and production. We help brands move fast, stay cost-effective, and never compromise on quality.