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Generally all OEMs have a distinctive approach in designing their sound packages. Considering the complexity and combination involved in this process, there is no general valid scheme, although there tend to be some common blocks. Also as automotive manufacturers face strong demands to cut CO2 levels there is a trend to reduce prototypes and introduce limitations on weight of sound controlling materials. The supplier of the sound package must therefore be able to support the OEMs in taking design decisions early, quickly and based just on drawings, or even just on sketches in the concept phase. A proposed way forward in designing fast and cost-effective sound packages is by skillfully combining target setting, material characterization measurements, virtual prototyping and optimization tools. The solution should not only be acoustically effective, but also lightweight and cheap.

The first applications of plastic panels in the underbody targeted weight savings (elimination of the PVC coating) and aerodynamic drag reduction. The potential for the integration of acoustic functions in such new elements, addressing both interior and exterior noise, was readily recognized and demonstrated in several studies. These also pointed out the synergic interaction of the new elements with common systems and components of the sound package. While it was rather straightforward to define an acoustic design and optimization process, based on material modeling combined with component, system and vehicle SEA and FEM simulation, it also became clear that the integration of acoustic functions involved many problems that needed to be addressed in a multidisciplinary approach.