It is not uncommon to see a vehicle on the streets or in a magazine and immediately go “Wow, what was the inspiration behind this” or “Yikes! What is this surely?”.
In the modern era of cars, the majority of automakers have developed design languages. These languages are themes that the cars of a particular era follow to bolster brand identity. During the design of new models, these languages greatly influence general appearance, and some features cut across models. Good examples of design languages are Mazda KODO and the kidney grille by BMW.
Design language aside, today we shall take a look through the process of designing a car and all the work that goes on in the background before you see a car on the road. At the end of this article, you should be left with a newfound respect for any beautiful car you see out there coupled with bewilderment at how some not-so-good-looking cars passed through all these stages and made it to life.
1. Inspiration phase
As with all creative processes, the first step is inspiration. Inspiration can be drawn from any number of things including animals and birds, lifestyles, mythical creatures, architecture, fashion, and even abstract ideas.
The hunt for inspiration needs to keep future trends in mind. Being futuristic is key as the design process can take many years and the produced car lifecycle is generally five or more years meaning a designer needs to create a piece of art that will stand the test of time.
2. Sketches
Once inspiration has been drawn, the designer then embarks to make rough sketches and doodles on paper. While they don’t showcase many features or answer many questions, these sketches are the first guidelines for a cars form.
3. Tape drawings
Some manufacturers such as BMW, add a step after rough sketches. Full-size tape drawings are pinned up on a wall. This step aims to get a lifesize estimation and feel for the various dimensions of the car.
At this step, precision is key and the designs are not only influenced by the sketches but also by functional requirements such as wheelbase, cargo volume, allowing for safety systems, car height, etc.
4. Computer Aided Drawings
After the dimensions and details have been confirmed, designers then recreate the sketches in 3D using specialized software. In this stage designers aim to create a union focussing on aesthetics, functionality, and ergonomics but within the realm of what is technically producible.
This is the first stage that is collaborative. Designers have to work with engineers and the entire team to ensure the feasibility and functionality of the creation. Virtual Reality is also extensively used at this step to give an early real-life feel of the vehicle.
5. Clay model
A clay model provides the most realistic view of the car. A 1:1 3D model of the car is made using heated clay. This process usually takes about a month. Using a clay model the various aspects of the car’s build such as the lines can be seen and examined up close.
Once a designer is happy with the model, a special film that mimics paint is then laid out over the model to accurately represent how the car will look in person.
The result of this process is a model that is accurate to the last detail of the car ready for the next step.
6. Interior
The interior designers create a series of full-scale sit-in boxes that represent various interior options. This phase is all about aesthetics and ergonomics and the interior layout with the best overall score is selected.
The soul of the car is greatly affected by this as an interior can shape whether a car is viewed as opulent, futuristic, fun and playful, or just plain old luxurious.
7. Repetitive refinement
The models go through a series of edits over time from all teams. These edits can be minor or major and are made to refine the final appearance of the car. Before the car goes to the next phase, it is ensured that all teams are content with the outlook of the car.
8. Prototypes aka Concept car
After the design team is fully satisfied, a fully functional prototype is developed. The prototypes are used for two major reasons i.e. testing of the car and gauging reaction of the public to the car.
It is key to note that many cars do not proceed from the prototype to the production phase and the ones that do, are often watered down less crazy-looking cars.
Concepts are sometimes just to show what automakers are capable of with a blank cheque.
9. Production
A successful prototype will then proceed to production planning. The company decides on manufacturing targets such as the number of units and release dates and then the car is sent out to be manufactured at the brand-designated manufacturing and assembly plant.
10. Evolution
During a model’s life cycle, it is common to have various styling and interior upgrades. They can be subtle changes in lighting or full-on facelifts to keep a model looking fresh.
With all these in mind, what car are you glad made it all the way? what car do you think should not have been made? Let us know in the comment section.
