Premium styling – without complex production line changes

Many OEMs face a similar problem: how to create ultra-flush windows with no lip or edge, without huge increases in price and complexity. In the past, OEMs had to pay a premium of around 40% minimum for this flush aesthetic and face complicated production line changes.

Understanding the needs of OEMs, our experts decided to create a design to cost solution. The challenge was to create a new, simpler mechanism to make the installation faster, while improving the design and quality of the finished effect – all without a significant impact on cost and complexity. 

Knowing OEMs, we knew they wanted something affordable, easy to install, duplicable on different models and ranges, without retooling their production lines or retraining installers. So, we devised and patented a new concept (which could be a one-piece module) using a conventional framed door approach but with the fully flush aesthetic of a frameless door.

• Improved aesthetics
• Easy assembly
• Weight savings
• Reduced cost compared to other frameless or flush glazing concepts
• Recycled and recyclable parts

By keeping things simple, we made it possible for OEMs to offer flush windows on any of their existing vehicles, creating a simple and cost-efficient way for them to differentiate between their brands and their models. Premium styling came with minimal extra cost and no impact on productivity or tack time. We were also able to adapt the approach to make use of recycled compounds and recyclable parts, offering OEMs further improvements in CO₂ impact.

Our new design went into production in 2022 and can currently be found on a variety of road cars, with further projects in production and development in Asia, North America and Europe for a number of OEMs and brands.

It’s a good example of how Hutchinson’s unique set of skills and expertise supports our clients to deliver breakthrough products while pivoting to a low-carbon future.