B9575 - CAR DESIGN AND STYLING

Learning outcomes

Learning and understanding the fundamentals of style-oriented design in the automotive field, through the systematic approach for the realization of a complete concept car, from the design approach, defining the technical specifications by means of the IDeS (Industrial Design Structure) method, to the implementation of the stylistic development process, by means of SDE (Stylistic Design Enineering). Developing advanced innovative vehicle projects in working groups, applying multidisciplinary knowledge to the design and physical and virtual prototyping of new vehicle models, using advanced digital technologies such as CAD and VR as well as 3D printing. The students, organized into working groups, will have to apply these technologies to give shape to emerging vehicle concepts. They will therefore develop the ability to work in teams, planning and managing the activities necessary to achieve technically valid design results

Course contents

The educational program provides a comprehensive and detailed overview of structured approaches to industrial product conception, with a practical focus on their implementation within the field of automotive engineering, guiding students through the preliminary design of new Cars, covering various segments: City Cars, Sedans, SUVs, Coupés, Cabriolets, and Station Wagons.

The two fundamental pillars of the process will be presented and analyzed:

• A system for the management and coordination of all activities pertaining to the creation of an industrial artifact.

• A technical-creative procedure aimed at the formal and aesthetic definition of the product.

Within the track dedicated to stylistic design, the following operational stages will be examined in detail through the method  Stylistic Design Engineering (SDE):

• Generation of preliminary sketches and ideas for new automotive models.

• Production of two-dimensional technical drawings that define the proportions and views of the new vehicles.

• Creation of three-dimensional digital models developed from the previous stages.

• Production of digital prototypes through photorealistic rendering techniques.

• Realization of physical scale models using additive manufacturing technologies.

The practical exercises will be based on assignments that realistically replicate the conditions and challenges of a real professional environment, simulating the various phases that characterize the development of a product, from its initial conception to its final definition.

The main phases covered will concern:

• Definition of the Vehicle Product Brief

• Project Setup (using Design for Six Sigma) for the new Vehicle

• Vehicle Chassis Design using 3D CAD software: extrusions, sheets, castings

• Chassis Verification using CAE software (FEM analysis)

• Construction of the Platform's Digital Twin: Chassis, Running Gear, Engine, IEE Systems

• New Vehicle Bodywork Design with SDE (as described before)

• Integration of the Bodywork with other components

• Vehicle Digital Twin and Rendering

• Physical and Virtual Prototypes

For a successful course completion, prior familiarity with the following is recommended:

• Expert use of two-dimensional Computer-Aided Design (CAD) software.

• Solid proficiency in using three-dimensional design tools, for both solid modeling and the modeling of complex shapes and surfaces.

Significant focus will be dedicated to the creation of automobile bodywork, using CAS (Computer-Aided Styling/Surfacing) software, intended for the advanced modeling of the single-shell car body.

Feasibility checks will be performed through: visibility tests, CFD (Computational Fluid Dynamics) analysis, interior packaging and ergonomics assessments, as well as aesthetic and dimensional evaluations.

Readings/Bibliography

De Silva W., Manzoni F. Thomas J., Il Codice de Silva, Artioli Editore, dicembre 2022

Giorgetto and Fabrizio Giugiaro, Masterpieces of style, Giorgio Nada Editore, maggio 2023

Giacosa Da., Progetti alla FIAT prima del computer, Automobilia, luglio 1989

Frizziero, L. et al., Innovation design driven by QFD and TRIZ to develop new urban transportation means, Australian Journal of Mechanical Engineering, 19(3), pp. 300-316, 2021

Frizziero, L. et al., A new car concept developed with stylistic design engineering (SDE), Inventions, 5(3),30, pp. 1-22

Giacosa, D. Motori Endotermici, Hoepli

Genta, G., L'Autotelaio, ATA

Eissen, K., Sketching: The Basics,Bis Pub

Freddi A., Imparare a Progettare, Pitagora, 2005

Frizziero, L., Liverani, A., Nannini, L., Design for six sigma (DFSS) applied to a new eco-motorbike, Machines, Volume 7, Issue 3, 2019, nr. 52

Frizziero, L. et al., Application of ides (Industrial design structure) to sustainable mobility: Case study of an innovative bicycl, Inventions, Volume 6, Issue 2, 2021m nr. 22

Further timely references will be given by the Professor during the lectures in the first block.

Teaching methods

The course employs a teaching methodology based on practical application, simulating the complete product development cycle characteristic of modern industry. The learning process unfolds through a collaborative path where participants, organized into working teams, are tasked with managing a complex project from its initial conception to its final definition, operating within realistic project constraints and timelines.

The systematic application of established design methodologies is fundamental, providing an operational framework to transform abstract requirements into concrete, well-defined project solutions. The outcome of this process materializes in the creation of a comprehensive concept, represented through advanced digital models and/or physical prototypes, intended for presentation and discussion during a final review.

Assessment methods

The final assessment will be based on a comprehensive automotive concept project, presented in its entirety at the conclusion of the course. The primary deliverable is a detailed presentation of the project, which may be supplemented by a digital or physical prototype to demonstrate and validate the proposed design solutions.

The development of this project will be supported by periodic progress reviews. Throughout the course, each team will present the status of their work to the instructor and peers. These review sessions are designed as formative milestones, providing guided feedback to steer the projects toward an optimal outcome while simultaneously simulating the standard checkpoints of a professional industrial process.

The final grade will be determined by a holistic evaluation of multiple criteria. This includes the inherent quality and innovative value of the final design. Furthermore, the assessment will consider the individual contribution of each student, the team's collaborative efficacy, and the overall professionalism demonstrated by the group throughout the project lifecycle. This approach ensures that the evaluation encompasses not only the final result but also the critical process and team-dynamic skills essential in a professional context.

Teaching tools

The educational support will leverage an integrated set of conceptual and technological tools. The theoretical foundation will be supported by digital teaching materials, including presentation slides and a selection of fundamental bibliographic references, which will provide the necessary methodological and cultural context.

The project activity will be realized through the use of a suite of specialized software, accompanying the entire development cycle: from the initial generation of ideas with digital sketching tools, to their technical definition via 2D and 3D CAD modeling, and finally to their advanced representation through photorealistic rendering techniques.

Finally, to give tangible form to the developed concept, use will be made, where pertinent, of rapid prototyping technologies such as 3D printing, and immersive visualization solutions such as Augmented Reality, enabling an aesthetic and functional evaluation of great impact.

Office hours

See the website of Leonardo Frizziero