Engine Cover
Premium component design for bespoke vehicles
Twisted Defender
Client: The client approached us while developing a new high-performance drivetrain, knowing their existing engine cover wouldn’t meet the level of refinement expected from their builds. Twisted needed a solution that honoured their aesthetic while delivering precision, durability and compliance. With experience in low-volume manufacturing and complex mechanical integrations, we were well-placed to help.
Approach: We began by reverse-engineering the existing component, capturing every dimension to create an accurate digital foundation. Early sketches explored form, proportion and visual identity before moving into detailed CAD development and full-scale 3D prototyping.
Challenges: Low production volumes ruled out traditional moulding, prompting a full review of alternative manufacturing routes. Material behaviour, heat exposure, fit tolerances and assembly clearances all required careful evaluation. CNC-machined FRP emerged as the optimal balance of quality, performance and cost.
Deliverables: We provided concept development, engineering design, prototyping, manufacturing guidance and supply-chain support, ensuring the final solution could be produced repeatedly and reliably.
Impact: The final engine cover delivered the precise fit, clean geometry and premium feel the client envisioned, now in production and integrated into customer vehicles.
“Twisted have bold ambitions to become the global leader in customising Land Rover Defenders. Whilst we have some capacity in-house, we needed to work with an organisation who can push the boundaries, apply breath-taking innovation and practical engineering experience.
Pd-m are cognitive thought leaders and practical designers who have the unique ability to convert concepts into commercially viable solutions.”