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This paper presents a versatile and economical knowledge‐based assembly design of blade and shell assemblies by employing behavioral modeling concepts. Behavioral modeling is a new generation CAD concept aimed at achieving ultimately optimum results with the efforts made in the early stage of the product development cycle. As a result, the assembly process of any odd‐configured parts such as torque converter blades, can be accurately planned, and made adaptable to all potential in‐process alterations due to either changes of components design or that of the assembly kinematics. Optimum assembly design is achieved when the volumetric interference meets a desired value based on an expert's determination. Experimental verification of the proposed optimum assembly design conducted in Luk, Inc. with two different blades' assemblies demonstrates satisfactory results.

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