Case study / BMW X3 30e

The charging cap the libraries missed.

A BMW X3 30e needed protection on its fender and charging cap. No pattern library had the pattern for this plug-in hybrid variant. The job needed a custom template.

Vehicle
BMW X3 30e
Variant
Plug-in hybrid
Missing coverage
Fender + charging cap
BMW charging cap held in the workshop with wet protection film and a cutout around the M badge.
The actual charging cap · film fitting in progress

01 The missing pattern

The right model. A different panel.

The car was an X3, but the job was specific to the 30e: the fender and its charging cap needed their own pattern. For this job, no pattern library covered that combination.

That small panel carries several details the template has to respect: its curved outline, the raised M badge and the edges where the film will stop or wrap. The charging-cap files and workshop photos below show those details being worked through.

02 The template work

One cap. Three edge treatments.

The template can be tailored to how the installer wants to work: flush edges, wrap allowances or corner relief cuts, each with an opening around the badge.

Flush edges charging-cap template with an outer cut line and badge opening.

01 / SVG

Flush edges

The film stops inside the cap edge, with an opening around the badge.

Inspect the SVG
Flush and wrap edges charging-cap template with an outer cut line and badge opening.

02 / SVG

Flush and wrap edges

Selected edges extend beyond the face of the cap, leaving film to turn around the edge.

Inspect the SVG
Wrap with relief cuts charging-cap template with an outer cut line and badge opening.

03 / SVG

Wrap with relief cuts

Relief cuts divide the wrap allowance at the corners. Dashed lines show where the film folds.

Inspect the SVG

03 On the part

The details, up close.

Two edge treatments on the actual cap: template 03 with relief cuts, and template 02 with flush corners and material left to wrap the edges.

Template 03 fitted to the charging cap, showing relief cuts in the film around the corners.
Photo 01 · SVG 03 / Relief cuts around the corners.
Close-up of template 02 on the charging cap, with flush corners and extra material along the edges for wrapping.
Photo 02 · SVG 02 / Flush corners, with material left to wrap the edges.
Wider view of the same template 02 fitting, showing flush corners and material extending past the edges for wrapping.
Photo 03 · SVG 02 / The same cut as photo 02, seen from further away.

Your next missing pattern

Start with the part in your bay.

A library gap does not change what the customer wants protected. PPF Engine gives installers a way to turn a 3D scan into a custom pattern, then refine the edges and cutouts for the job.