> Pre-production prototypes to verify A-class design elements  

> collaboration

BSTG contracted Bayly to produce prototype door and window trim components from their designs for the Holden VE Commodore range.

> process

The trim parts are characteristically long, up to 1200mm and thin, around 1.2mm.  Manufacturing these prototypes using a suitable cost effective process was a challenge.

Bayly developed a means of casting these parts using a specially formulated material that best represented the trims within the constraints of the design.

Each trim component was hand finished and painted.  Delivery to BSTG in Adelaide required that special re-usable packaging be developed to ship the many sets required over a period of about 4 months.

> innovation 

The development of the materials and casting process was crucial to the success of the project.