At Convert Design, we specialise in solving complex engineering problems without compromising on performance, safety or visual impact. As mechanical engineering design specialists, we work fast, think practically and stay laser-focused on what matters most — delivering high-performance, production-ready solutions that meet tight timelines and tighter budgets.
When Aston Martin approached us to help re-engineer the V12 Vantage bonnet vent, they weren’t just asking for a redesign. They needed an entirely new approach that could deliver on multiple fronts: reduce cost significantly, preserve the car’s signature styling and ensure smooth integration into their production process.
It was a high-stakes challenge. But that’s exactly the kind of work we do best.
The Challenge: Redesign, Reduce Cost, Retain Appeal
The original bonnet vents were crafted from lacquered 2×2 twill carbon fibre — a material synonymous with premium performance and visual sophistication. These vents were critical to managing engine bay heat in a tightly packed environment and had become a recognisable styling element for the V12 Vantage.
But the issue was cost. The carbon fibre vents involved expensive tooling and production processes that made them difficult to scale. Aston Martin needed a solution that would pay back any new tooling investment within the first year. At the same time, internal stakeholders — particularly from sales — were concerned that any spec reduction could harm the brand’s premium image and lower perceived value among customers.
This is where mechanical engineering design specialists like our team at Convert Design come in.
Our Approach: Practical, Collaborative, Precision-Driven
We began by deeply analysing the original vent’s function, structure and materials. We wanted to fully understand what made it work — both technically and aesthetically — so that any changes we introduced would not compromise performance or design integrity.
Using Siemens NX, our go-to platform for advanced 3D modelling and DFM analysis, we worked with the design studio to create an alternative look they liked. Our team identified ways to deliver the specified design more cost effectively and presented it to the company including the CEO and all key directors for approval.
Collaboration was key throughout. We worked closely with Aston Martin’s design studio, management team and key suppliers to ensure alignment on every aspect of the solution — from tool design and material choice to surface finish and assembly feasibility. Our experience with plastic injection moulding and tooling design meant we could address concerns early and propose manufacturable alternatives that didn’t feel like compromises.
The Result: A Win for Engineering, Design and the Customer
The final design replaced the carbon fibre louvre system with a high-quality mesh vent solution that was not only visually striking, but also significantly more cost-effective to produce. The results spoke for themselves:
- 75% reduction in part cost, with no loss of visual or functional quality.
- 50% of customers preferred the new mesh style, turning a cost-saving measure into a popular styling option.
- Adopted for a limited production run of 15 vehicles, with a successful production line trial.
- Supplier-approved following full quality and fit validation, ensuring seamless integration.
- Original carbon vents still available as an upgrade, maintaining flexibility and customer choice.
This wasn’t just a cost-down exercise. It was a demonstration of how thoughtful mechanical design, carried out by experienced specialists, can solve commercial problems in a way that strengthens a product — rather than diluting it.
Why Clients Choose Convert Design
Here at Convert Design, we work fast with acute awareness of budget and price. Yet, we never compromise on safety or performance — which is why we’re trusted by clients in the aerospace, automotive and outboard marine sectors. Our reputation is built on delivering manufacturing-ready designs that work under pressure, hold up to scrutiny and get signed off without surprises.
We’re not just design engineers. We’re problem solvers. Whether you’re developing a new product, improving a legacy component or responding to supply chain shifts, we can help you move quickly, confidently and with a clear business case.
From concept sketch to tool-ready data, we deliver at every stage.
From Automotive to Innovation: Beyond the Bonnet Vent
The Aston Martin bonnet vent project is just one example of how we bring together creativity, precision and manufacturing know-how. Our work spans far beyond automotive. We’ve also recently designed, patented and developed Bottld — our own reverse vending machine created to tackle the ongoing problem of plastic collection and recycling.
This kind of project reflects what we’re passionate about at Convert Design: working on high-impact problems, developing practical solutions and getting them out into the real world.
Let’s Talk About Your Next Challenge
If you’re looking for mechanical engineering design specialists who know how to work fast, stay flexible and deliver exceptional results, talk to us at Convert Design.
We combine practical manufacturing knowledge with cutting-edge design tools to help you reduce cost, improve performance and stay ahead of your competition.
Get in touch today to discuss your project, request a consultation or see more of what we’ve done.
