Behind every autonomous driving breakthrough is a vehicle that has been carefully engineered, instrumented, and prepared for the kinds of tests that push technology forward.

At aiMotive, that responsibility falls to our Vehicle Hardware Integration Engineering team – a group of specialists who turn concepts into fully sensorized, robotized, calibration-ready platforms that can withstand the demands of real-world testing.
For more than a decade, this team has built test vehicles across continents, working under tight timelines, challenging on-site conditions, and constantly evolving technologies. Their work may not always be the most visible part of automated driving development, but without their craftsmanship, no perception model could be trained, no simulation could be validated, and no autonomous software could be tested safely.

From idea to fully functional test vehicle

The integration process always begins with a concept. Sometimes, it’s a prototype platform that requires a comprehensive sensor suite; other times, it’s an existing vehicle that needs to be transformed into a research or test asset. Regardless of the requirements, the team’s goal remains the same: to deliver a stable, reliable, and cleanly integrated test vehicle that supports accurate data collection and robust testing workflows.

This means handling every physical aspect of the build – from mechanical design to wiring, from sensor placement to robotization. Because on-road testing is often continuous and tightly scheduled, speed matters almost as much as engineering precision. Over years of experience, our team has refined a process that allows them to build vehicles quickly without compromising quality.

Sensor integration that gets the details right

Autonomous driving begins with accurately sensing the world, and that requires sensors to be installed with extreme precision. Cameras, LiDARs, radars, GNSS receivers, antennas – every component must be positioned to maximize data quality while withstanding heat, vibration, weather, and extended test cycles.

To ensure perfect placement, the engineering team uses aiSim to simulate different sensor configurations before any drilling or mounting occurs. This reduces trial-and-error, shortens build time, and ensures optimal coverage for perception algorithms. Mechanical mounts, housings, and environmental protections are then custom-designed and manufactured, often using additive manufacturing to achieve fast turnarounds and high accuracy.

Engineering custom solutions for unique challenges

Not all sensor layouts or test requirements can be solved with off-the-shelf parts. That’s why custom design engineering is a core part of the team’s work. Using AI-assisted generative 3D modelling, vehicle-grade 3D scanning, and advanced manufacturing processes, the team creates fully bespoke components for each build – from sensor brackets and precision fixtures to complete enclosures and thermal solutions for onboard compute units.

Their generative design workflow evaluates hundreds of structural variants in a single week, ensuring that each mount delivers maximum strength with minimal weight and the smallest possible environmental footprint. This approach replaces the traditional multi-iteration cycle, eliminating weeks of manual redesign and accelerating the path from concept to validated hardware.

Thanks to rapid prototyping and an extensive supplier network across CNC machining, sheet metal, composites, and injection molding, the team can iterate quickly and deliver production-quality parts even for the most specialized needs. AI-driven engineering is a company-wide capability, and the Vehicle Hardware Integration group fully leverages it to deliver faster, lighter, and more robust solutions than ever before.

Wiring and electronics designed like an OEM would

A test vehicle’s wiring is often quite complex; dozens of sensors, compute units, timing modules, and networking components must be connected securely and safely. The integration team builds automotive-grade wiring harnesses tailored to each vehicle, using modular, clearly labeled routing that ensures easy maintenance and fast troubleshooting. Every harness is fully documented using professional engineering tools, giving complete traceability – essential when vehicles are tested across large fleets or multiple countries.

Reversible, reusable, and repeatable

A hallmark of the team’s approach is non-destructive integration. Sensors and components are mounted in a way that allows for their reversal, removal, or reconfiguration without damaging the vehicle. This is especially important for OEM partnerships or joint development programs, where vehicles must remain flexible long after the original build.
For scenarios requiring exact repeatability, such as braking tests, steering maneuvers, and high-speed dynamics, the team integrates steering, pedal, and driving robots into test vehicles. One of these robotized platforms has even been granted a German AV permit for automated operation, highlighting the reliability and safety of the integration.

An experienced, global partner

The integration engineering team also designs and manufactures specialized tools to support downstream workflows, including calibration fixtures, alignment rigs, and reference sensor mounts, which ensure the accuracy of both real-world and simulated testing.

Instead of operating as an external design office that pushes back on unclear requirements, our Vehicle Hardware Integration team takes a fundamentally different approach. They provide proper end-to-end support – from defining the optimal placement of sensors all the way to delivering fully built, hardware-integrated test vehicles.

Because our team works closely with the same systems that power autonomous-vehicle development and testing, they continuously refine processes based on fundamental engineering needs. When information is missing or incomplete, they fill the gaps with our technical expertise, ensuring that every project is delivered on time and with a fully functioning system – not just documentation or designs.

If this capability sparks your interest, reach out to our Professional Services team to learn how you can access the services highlighted in this article.