Innovative Flush Handle: Next-Generation Design for the new Jaguar Land Rover Models

This master thesis, developed in collaboration with Minebea AccessSolutions, presents a comprehensive study on the design, improvement and optimization of an innovative flush handle for Jaguar Land Rover vehicles. The research was carried out within the framework of the L481 project, derived as a carry-over from the L460 model already in production. The first part of the work focuses on a detailed analysis of the existing L460 handle, assessing its mechanical architecture, functional behavior, and integration with electronic subsystems. This baseline evaluation has allowed the identification of critical aspects influencing packaging feasibility, structural safety, and ergonomic performance. Building on these findings, the development of the L481 model required addressing several engineering challenges, including the limited packaging space, the integration of new electronic components, aiming for the optimization of both design and structural elements, with innovation and customer satisfaction always as guiding principles. Structural analyses, risk analysis, validation tests, and simulations supported the evolution of the flush handle system from the L460 to the L481 model. The outcome of this work demonstrates how a systematic engineering approach can successfully manage the trade-offs between innovation (through new sensors and user-experience features, with a continuous pursuit of miniaturization), reliability, and design constraints imposed by the handle as a key element in the stylistic identity of modern vehicles.