Lecture 2

12/5/2022
Advanced Concept Design Process

(usually takes 6 months to a year to complete)
Bench
Product Design & Product
Functional Marking,
Planning & Package Planning &
Objective Sizing &
Research Ideation Research
Proportion
Researching the Primary goals The basic Existing Once the basic
intended for the project layout of major products with dimensions for
market, are set. components similar hard points are
customers and These should and any attributes are formulated, the
competitions. be considered innovative compared to scale or full size
Emerging
from both features are validate the clay model is
Technology and
customer and sketched design built and
Manufacturing
Strategies are manufacturer’s loosely in direction. This developed with
also discussed. perspective various process is used the package.
configurations to develop the
basic
proportions
Assad Anis, Automotive Department, NED University of Engg. & Tech.
The Production Design Process

(usually takes 3 to 4 years with 1 year in styling studio)
Finished Prototype
Production Production
Advanced build Testing
Design Engineering
Concept & Launch
Advanced This group develop After testing

concept is exterior and interior minor few design
handed over to surface over a package changes are
production that is 100% feasible for required
Design production and meets
all costs targets as well
as need for intended
market.
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The Systems in a Package

• Every package is
comprised of same groups
of system
• Each of these system will
vary according to the
functional objective of the
vehicle.
• Each of the components
that make up the system
is packaged within spatial
envelop which allows for
motion, manufacturing
tolerances, clearances,
heat insulations,
maintenance and
assembly.
Vehicle Types and Market Segments

• In early stage of design market segment is decided.
• The type of vehicle is decided before start of project
• For a ‘blue sky’ project, customer requirements may be the only consideration
during ideation and segment is associated later.
Anatomy of Passenger Car Package

• The elements in the package will vary from concept to concept, but the items shown feature in most vehicles.
• Each of these elements will need to be studied by studio engineering team during the development of the project to provide
high level of confidence in vehicle design
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Summarizing Automotive Design Process
Steps of the Process

• Product Planning
• The Design Brief
• Concept Generation
• Theme Selection
• 3D and Computer Model Generation
• Design Evaluation
• Styling Freeze
• Prototype Development / Product Testing
• Product Launch
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Product Planning
Brainstorming before any work begins
• Market research to be sure the

product is needed
• Factory capacity is available

• Manufacturing processes
• Necessary equipment
Concept Generation
Putting ideas on paper
• Basic thumbnail sketches to start
• Followed by more detailed drawings
• Usually the exterior is designed first, but
occasionally the interior design affects th4e
exterior shape
Theme Selection
Evaluation of sketches
• Designer sketches are reviewed and a theme selection is made on which

design best meets the following:
• Matching the design brief
• Most interesting look
• Now designers have a more detailed design direction to steer future
development of ideas of the new vehicle
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3-D Model Development

Helping see the new vehicle “in the round”
Models are constructed out of clay to help visualize the designs

• Scale models are developed first
• Full size models are developed as the project moves forward
Design Evaluation
Total evaluation of the project
• Full size models and drawings are reviewed
• Appearance is evaluated
• Ergonomics is evaluated
• The new vehicle is compared to competitors

cars
• Potential customers are tested for reactions
Styling Freeze
Specifications are finalized
• Body style and mechanical specifications

are finalized
• Financial viability is reassessed
• Changes beyond this point would be very

expensive and result in production delays
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Prototype Development
and Product Testing
• Hand-built prototypes are
made and tested under

normal and extreme driving
conditions
• Crash testing is also
performed and will

continue on production
cars at a later date
Product Launch
Formal introduction to the general public
• The new vehicle is unveiled at a major auto show in a blaze of well organized
publicity
• The ultimate success of the vehicle is based on the strength of sales and the
return on investment over the vehicles lifespan
Body Design- Styling Process
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Introduction
• Little written material is available on this subject.
• The work of the automobile stylist remains little
understood by many, including other industrial designers.
• Armi in 1988 states that:
‘Car Styling is amongst the least understood of the
commercial arts’.
How cars went from boxy to curvy
How cars went from boxy to curvy.mp4
Introduction- HEJ Studio

• Harley Earl (was an American automotive
designer and business executive. He was the
initial designated head of design at General
Motors, later becoming vice president, the first
top executive ever appointed in design of a major
corporation in American history) developed
first purpose-built styling department at
General Motors in 1927.
• The method includes

• creating designs on paper as 2D sketches, then
converting them to full size 2D orthogonal
illustrations.
• These are used to create templates, etc., to create
full-size three-dimensional models, usually in clay,
though wood and plaster are sometimes used.
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Concept Car
What Goes into Designing a Concept Car.mp4
The fifth-generation Ford Mustang's design was inspired by the Mustangs of the 1960s. What sports car is called a
"Fairlady" in Japan?
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HEJ Studio
• The full size mock-up is then used as the basis for all body surface
information required by the engineering department for
• structural design and
• Tooling to be developed.
• The stylist job includes generation of

• Concept sketches
• their conversion to full size tape drawings
• renderings and
• the creation of scale or full size clay models
HEJ Studio- Contd.

• Sketches are produced and selected, via a series of presentations and
discussions, to create further development.
• This achieves the progression to full size elevational views and onto the full size
model.
• The creation of the clay model is a long, tedious and very costly process, carried
out with the aid of teams of expert sculptors.
• These are the ‘modelers’ working under the supervision and direction of the
stylists during the design development stages.
• The model, when finished and also at various earlier stages, is carefully
measured, either manually or electronically, to supply information to the body
engineers.
• It is this activity that was the focus of much of the original interfacing of CAD
with the styling studios.
HEJ Studio- Contd.
• The entire styling process is subjected to various decision-making

interventions, within the studio and by more senior management.
• The system devised by Harley Earl is the usual role model, but there
are many variants of it, including the totally adhoc approach common
in vehicle design consultancies and smaller studios.
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The studios, working environment and structure
• conventional basic facilities that allow

the styling process to be performed.
• Inside the styling building, studio

space for designing and modelling the
exteriors and interiors of vehicles is
provided, plus the necessary workshop
services and administration to support
the activity.
• Strict security is imposed.
The studios, working environment and structure- Contd.
• The building is divided into two main areas by a wide corridor:
• The Studio and
• Workshops
• Also a viewing area or showroom at one end of the building, and an outdoor viewing courtyard attached,
usually surrounded by a high wall or fence and tree screen to keep prying eyes and cameras at bay.
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• On average the European and Japanese Studios (and the individual line American
Studios), employ about 15 or so stylists and about 20–30 clay modellers.
• The smaller design consultancies may have as few as 3 or 4 stylists with
proportionally smaller teams of modellers, who may well double as fabrication
shop workers at other times.
• Most stylists prefer to be close to the models.
• Ovens to soften the hard waxy clay for use will be positioned where they are easily vented and
convenient for the modelers.
• In the exterior studios one or more modelling tracks, with calibrated surface plates on the
floor, are installed.
• The model is placed on locating pins, and a large metal arched structure (referred to as a
‘bridge’) runs on guides either on or below the floor on either side of it.
• This bridge has a sliding calibrated cross beam with adjustable measuring bars which can be
slid in and out and up and down on this beam and its vertical supports.
• This enables the model to be accurately calibrated at any point on its surface.
• A simpler system using a single vertical post sliding on a track, with adjustable measuring bar,
is also quite common.
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Automotive Clay Design Process.mp4
Oddly Satisfying Car Clay Modeling You Must See.mp4
y2mate.com - clay_modeling_demo_2015_ford_mustang_gt_on_everyman_driver_RK5pXE5kkB4_1080p.mp4
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The Package
• The ‘package’ is the industry’s term for the three dimensional (3D) view, full
sized orthogonal drawings which show the basic mechanical and ergonomic
requirements of the intended vehicle.
Vehicle Design Process (BMW)
 Looking ahead: Identifying trends
 A question of character: Hand-drawn sketches
 Precision: Tape drawings
 Virtual experts: Digital models
 Shaping: Clay models
 Internal view: Drawing the interior car design
 Perfectionism: Fine-tuning
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Looking Ahead: Identifying Trends

 Designers have to understand far in advance what will be
regarded as modern and cutting-edge in tomorrow’s world
 Designers gain their inspiration from a wide variety of sources

ranging from fashion and architecture all over the world to
nature.
 Concept cars are also used as inspiration
A question of character: Hand Drawn Sketches

 The competition begins with hand-drawn sketches,
where designers initially express their ideas in
countless hand-drawn sketches
 The designers must comply with requirements for the

defined character of the future vehicle as well as
technical conditions such as the wheelbase, trunk
volume or safety requirements.
 “My first point of contact with a new model is a blank

sheet of paper and a pencil,” says Anders Thøgersen,
exterior designer of the BMW X5. “In your mind, you
have a certain spirit and character that you want to
bring to the car. These initial hand-drawn sketches do
not answer all the questions, but they serve as an
abstract guide to the subsequent design process.”
Precision: Tape Drawings

 Alongside the sketches the designers draw their plans on a wall
on a 1:1 scale in what is known as tape drawings.
 They stick the proportions of the vehicle onto a base plan using
flexible tape.
 Base plans are a kind of map of the future vehicle with all
technical and structural features.
 Tape drawings provide the template for the next steps.
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Virtual Experts: Digital Models

 At this stage state-of-the-art digital technologies
come to play in the design process.
 From two-dimensional sketches, CAS (computer-

aided styling) designers create a virtual three-
dimensional vehicle. Among other things, they use
Virtual Reality.
 The design process becomes more efficient and also

delivers a context.
 Using VR, The new model can be displayed in a

respective living environment.
Shaping: Clay Models

 The car designs have been two-dimensional, but now
the form-finding process becomes three-dimensional.
 The designers, who concluded the selection process

successfully, are given the opportunity to work up
their designs three-dimensionally on a 1:1 scale.
 The models are made of clay
 A clay prototype is essential for working up surfaces,

lines and details perfectly
 Once the clay model is ready, the designers wrap it in

special sheeting that imitates the effect of car
paintwork.(Takes about a month)
 Makes it possible to assess the lines, surfaces and

proportions of a clay model in different light
conditions
 Goes forward to the next round in the decision-

making process. About two years before the vehicle
goes into production, the Board of Management
selects the winner from the two remaining car
designs.
Internal View: Drawing the Internal Car

Design
 Interior designers sketch and refine their models
at the same time as exterior designers.
 They also work with clay in this process. In so-

called seat boxes, they also make the entire
interior come alive from seats and details to
surfaces and materials.
 VR headsets provide support. Making it possible

to look round a virtual car interior as though you
were sitting in it.
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Perfectionism: Fine Tuning

 A dedicated team of designers is then called for the detailed car design as well as for colours and materials.
 Both on the exterior and in the interior of the vehicle, these fine-tuning experts perfect all the elements
down to hundredths of a millimetre.
 Close coordination among car designers, engineers and production technicians is especially important at
this stage.
16

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12/5/2022

Advanced Concept Design Process

Assad Anis, Automotive Department, NED University of Engg. & Tech.

The Production Design Process

Advanced This group develop After testing

Assad Anis, Automotive Department, NED University of Engg. & Tech.

The Systems in a Package

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Vehicle Types and Market Segments

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Anatomy of Passenger Car Package

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Summarizing Automotive Design Process

Steps of the Process

• The Design Brief

• 3D and Computer Model Generation

• Prototype Development / Product Testing

Assad Anis, Automotive Department, NED University of Engg. & Tech.

• Market research to be sure the

• Factory capacity is available

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Assad Anis, Automotive Department, NED University of Engg. & Tech.

• Designer sketches are reviewed and a theme selection is made on which

Assad Anis, Automotive Department, NED University of Engg. & Tech.

3-D Model Development

Models are constructed out of clay to help visualize the designs

Assad Anis, Automotive Department, NED University of Engg. & Tech.

• The new vehicle is compared to competitors

• Potential customers are tested for reactions

Assad Anis, Automotive Department, NED University of Engg. & Tech.

• Body style and mechanical specifications

• Financial viability is reassessed

• Changes beyond this point would be very

Assad Anis, Automotive Department, NED University of Engg. & Tech.

• Hand-built prototypes are

made and tested under

• Crash testing is also

performed and will

return on investment over the vehicles lifespan

Body Design- Styling Process

• The work of the automobile stylist remains little

understood by many, including other industrial designers.

• Armi in 1988 states that:

‘Car Styling is amongst the least understood of the

How cars went from boxy to curvy

How cars went from boxy to curvy.mp4

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Introduction- HEJ Studio

• The method includes

Assad Anis, Automotive Department, NED University of Engg. & Tech.

What Goes into Designing a Concept Car.mp4

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Assad Anis, Automotive Department, NED University of Engg. & Tech.

Assad Anis, Automotive Department, NED University of Engg. & Tech.

• The stylist job includes generation of

• their conversion to full size tape drawings

• the creation of scale or full size clay models

Assad Anis, Automotive Department, NED University of Engg. & Tech.

HEJ Studio- Contd.

HEJ Studio- Contd.

• The entire styling process is subjected to various decision-making

Assad Anis, Automotive Department, NED University of Engg. & Tech.