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// Dual Clutch Transmission Design

Precision Housings for an 8-Speed Supercar DCT

We joined a major automotive program to transform basic prototype housings into highly complex, production-optimised castings that reliably contain the extreme forces of a high-performance dual-clutch transmission.

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  • Project Duration Multi-year program
  • Gearbox Speeds 8-Speed DCT
  • System Leadership Authored full gearbox PDS
  • Core Components Complex stressed castings

// The problem & the solution

The Core Challenge & Solution

The Problem

From Prototype Block to Precision Core

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Basic Architecture: Early housings were blocky and not yet optimised.

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Extreme Loads: Had to endure high shifting forces and engine torque.

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System Complexity: Needed to hold many parts with tight tolerances.

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Production Gateway: Designed for scalable casting and CNC machining.

The Solution

A Holistic Design, Analysis, and Production Partnership

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System Leadership: Created the master PDS to align the entire gearbox design.

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Integrated Design: Collaborated with all system owners to refine housings and resolve space conflicts.

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Analysis-Driven: Used FEA throughout to balance strength and weight.

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Production Partnership: Applied DFM in close collaboration with casting suppliers and machinists.

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// Technical Highlights

From Specification to Signed-Off Part

Focus Engineering Action Result
System Integration
Created gearbox PDS and aligned housings
Cohesive core for hundreds of parts
Strength & Weight
Applied FEA in design
Strong, lightweight castings
Production Viability
DFM with suppliers
Ready for volume manufacturing
Quality Assurance
Inspected prototypes
Parts met design and tolerance requirements

// Value Delivered & Results

A Production-Ready Transmission Core

For the Program

  • Led gearbox engineering, owning the core structure from spec to production sign-off.

For Performance

  • Delivered lightweight, strong housings built to handle supercar-level loads.

For Manufacturing

  • Bridged prototype to production, optimising the design for casting and machining.
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Client Feedback:

"I had the pleasure of working alongside Core Mech on a day-to-day basis to deliver the most complex machined casting for an 8 speed DCT transmission for an OEM customer. Kieran's support, patience and thorough explanation of the technical challenges through the complex development process allowed me as the Project Manager to confidently manage both the supplier and the customers’ expectations daily from an informed and knowledgeable position and made my job so much easier. His flexible and adaptable approach to work, expertise and his ability to work at all levels was a real asset, especially when I was unable to support some supplier and customer meetings, as I could entrust him without worry to pick up the ball and run with it in my absence. A knowledgeable, very good all-rounder that is hard to find these days and is a real pleasure to work with."

// Engineering Process

A Proven Engineering
Workflow

Our engineering process is designed to deliver mechanical solutions that are accurate, manufacturable, and fully aligned with your project goals.

01

Discovery

We define your goals, requirements, and technical constraints.

02

Concept

Quick design options are explored to find the best approach.

03

CAD

The chosen idea becomes a precise, production-ready 3D model.

04

Validation

Simulations check performance, strength, and reliability.

05

Prototype

We support prototype creation and refine based on testing.

06

Final Delivery

Final design, drawings, and documentation prepared for manufacture.

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