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MOTORING MADE SIMPLE
What are the stages in successful car design?
The conception and birth of an automobile is just about as complex and riddled with anxious moments as any in the natural world. The whole process, starting from visualizing a design concept for the new car, the virtual model simulation, prototyping, and finally putting into production, is an intricate progression that involves a number of other factors.
The first, or shall we say, pre-natal stage in the whole development sequence is the formation of an idea - when the seeds of inspiration are sown in the minds of the car designer. The car's design theme is outlined in a number of sketches and line drawings. Exteriors, interiors and special additions are defined on paper and then on a computer using a platform like computer-aided design (CAD) software. Once the general design of the car is fixed on the virtual platform, then other factors such as the chassis, aerodynamics and aesthetic elements for the exteriors, the quality of materials and passenger safety issues are incorporated into the car's planned interiors.
How does a concept become feasible?
The next in line is conceptualizing the technologies that will be used in the proposed car. Technologies that will be needed for compliance with legislations not only regarding issues such as emissions and safety, but also for meeting the performance profile of the car are firmed up. Often, a certain level of testing and simulation is done virtually, after finalizing elements such as exterior design, type of materials, interior design and layout, and size and type of powertrains to be used. Many manufacturers today take the step of prototyping one level forward in the virtual world, where other simulations including movement, aerodynamics and crash testing is all done using a virtual mock-up. In other cases, virtual prototyping is confined more to getting a fix on the interiors of the car, which in turn is usually done for finalizing the driver position, accessibility of instruments and other ergonomics issues.
When does a car first take physical form?
In most cases, the next step or a parallel development would be the creation of a clay or a Styrofoam model, which is relatively cheap and easy to modify, while it can still offer a convincing physical mock-up of the proposed car. Then, a mock up in wood or other such material is attempted to get a `feel' of the car. In order to shorten the design cycle time, manufacturers either skip some of these process stages or try to do the same in a virtual environment.
Different prototypes are also made for different applications - such as for a show, for crash testing and for development of tools, dies and jigs.
The last few stages involve finalizing the geometry for development of fixtures, dies and tools, crash testing and laying the course for production line management. The car can then roll out of the production line. Pretty long birthing process, eh?
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