Mikel Arnao · Product Design Engineer
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p. 09Work 01 · Automotive · Product

SEAT Ateca side mirror

A mirror that folds itself before it hits something, and keeps the driver seeing when it does.

My role
Worked across the whole project. Led the regulatory analysis (ECE R46) in the product-analysis phase and most of the development phase: analysis and redesign of the new circuit, the material specification manual, the mould machining roadmap and the justification of the selected material. Led the final renders.
Year
2025
Context
Academic · PBL 4, 2nd year · Mondragon Unibertsitatea
Team
Ainhoa Alonso, Mikel Arnao, Maren Leston, Ane Pelayo, Garazi Portillo
Tools
SolidWorks, SolidWorks Simulation, CES EduPack, KeyShot, resin 3D printing
013D · drag to rotate

    Exploded view Simplified model of SEAT Ateca side mirror, generated in code.

    0%
    7.0 Whenergy for a 50-minute, 25 km trip, inside the 4–8 Wh target
    0.016 mmdeflection under aerodynamic load at 180 km/h
    5new components: folding motor, camera, radar, ultrasonic sensor, blind-spot LED
    Final render of the redesigned mirror with dynamic LED indicator.
    Fig. 02Final render of the redesigned mirror with dynamic LED indicator.
    § 01

    Context and brief

    The Ateca is a compact family SUV. Of three archetypes, the team chose Maite, a mother who picks her children up from school on a narrow, chaotic street and is afraid of clipping the mirror while manoeuvring.

    Brief: keep the Ateca family look, remove that stress with assistance systems and stay fully within ECE Regulation 46.

    Storyboard of the school pick-up used to find the pain point.
    Fig. 03Storyboard of the school pick-up used to find the pain point.
    § 02

    Research

    A benchmark of six rival SUV mirrors, mapped by price and technology, showed no affordable high-tech option. The regulatory study set the hard limits:

    • Minimum edge radius of 2.5 mm on housing and glass
    • Class III field of view: 20 m long and 4 m wide
    • No part above 2 m from the ground; vehicle width with mirrors under 2.55 m
    • Heated glass and LED indicator compliant with EU electrical and lighting rules
    § 03

    Concepts

    Brainstorming and four-step sketching produced three preliminary designs: one with a rain deflector, an aerodynamic one with blind-spot indicator, and a robust one with a hidden auxiliary mirror. A Pugh matrix chose concept 2, positive on viability, aesthetics, function and regulations.

    Sketch of the chosen direction.
    Fig. 04Sketch of the chosen direction.
    Exploration of the folding geometry.
    Fig. 05Exploration of the folding geometry.
    § 04

    Development

    An ultrasonic sensor folds the mirror when an obstacle gets close; a camera streams to the central screen while it is folded; a radar drives a blind-spot LED. The circuit was redesigned at 12 V with the sensors in parallel to the EFB battery.

    SolidWorks Simulation checked aerodynamic load, a 33 J pedestrian impact, fatigue at one million cycles, 500 N vertical and 300 N lateral loads, modal and thermal behaviour.

    Exploded CAD of the assembly.
    Fig. 06Exploded CAD of the assembly.
    New electrical circuit.
    Fig. 07New electrical circuit.
    Positive mould for the housing.
    Fig. 08Positive mould for the housing.
    § 05

    Specification

    The material specification manual turned functional, mechanical, thermal and chemical requirements into CES EduPack constraints and performance indices. The top five candidates were weighted after min–max normalisation; PCTFE was chosen for its UV, humidity and chemical resistance. Machining roadmaps were written for both mould halves.

    § 06

    Result

    A 1:1 aesthetic prototype printed in resin, filled, primed and painted, with an amber indicator and a laser-cut mirror on a hand-shaped curved base.

    Aesthetic prototype, housing.
    Fig. 09Aesthetic prototype, housing.
    Aesthetic prototype, mirror side.
    Fig. 10Aesthetic prototype, mirror side.
    Render of the mirror glass and camera.
    Fig. 11Render of the mirror glass and camera.
    Render on the vehicle.
    Fig. 12Render on the vehicle.
    § 07

    Reflection

    Simulation in SolidWorks went beyond the syllabus. The next step would be a functional prototype to test ergonomics, tolerances and assembly that virtual tools do not show.

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