Automobile Production process

Learn how over 30,000 parts are assembled into a car

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Sketching & Rendering
Taping Drawing
Digital(CAS) Modeling
VR Presentation
1:1 Scale Clay Modeling
Emotional Design
Body Structure Design
NVH Analysis
Powertrain Design & Analysis
Anechoic Chamber Test
Chassis Design
Wind Tunnel Test
Low Temperature Test
Snow/Rainfall Test
High Temperature Test
Road Simulator
Crash Test
Turning Trial Road Tire Test
Belgian Road Test
Desert Driving Test
Cast
Press
Welding
Painting
Assembly
Inspection
Road Driving Test

STEP1. Designing

The car's exterior is defined.

  • Sketch and Rendering

    Concept is substantiated through idea sketching following analysis of consumer trends and lifecycles.

  • Tape Drawing

    The full size sketch of the concept is created on a upright surface using black photographic tape to determine the match between the design purpose and the actual image. This is also used to set the basic layout.

  • Digital Modeling

    The design is recreated through a computer-generated 3D image whose data is then used for assessing the design and aerodynamics.

  • VR Model Review

    Virtual reality technology is used to review a design from various perspectives and ultimately determine the direction of the design.

  • 1:1 Scale Clay Modeling

    A 5-axis CNC milling machine creates a life-size model of the car which is then completed under the precise hands of modelers.

  • Emotional Desgin

    A diverse range of color options is developed to best match the design of the car and add more life and style to it. The precise color palette chosen is based on extensive analysis of cars and consumer preferences.

STEP2. Engineering

The car's features and performance are determined.

  • Body Structure Design

    The body design must consider such factors as rigidity, impact resistance, aerodynamics, noise and fuel economy to ensure a fine balance of safety, convenience, performance and value.

  • NVH Analysis

    The sources of vibration and how it is transmitted are identified to fully control the vibration and noise emanating from the car when driving.

  • Powertrain

    The car engine and transmission are developed.

  • Chassis Designing

    Chassis design covers such functions as suspension, steering, fuel, cooling, intake/exhaust, control and braking.

  • Function Designing

    Interior and exterior features are designed to give occupants a convenient, pleasant and safe experience.

STEP3. Test

The car is put to the test under various conditions.

  • Wind Tunnel Test

    An artificial wind of up to 200 km/h is applied to the car to measure its aerodynamics and resistance noise in order to identify improvements.

  • Low Temperature Test

    The car is operated at a temperature of as low as 40 degrees below zero to test its duration.

  • Snow & Rain Test

    The car is operated under artificial snow and rain to test its resistance.

  • High Temperature Test

    The car is operated in a temperature of as high as 60 degrees to test its duration.

  • Road Simulation

    The car's driving performance and the robustness of its components are tested on various road surfaces.

  • Impact Test

    The car is subjected to an impact from multiple directions in compliance with international safety regulations.

  • Water Tightness Test

    This test is intended to check the water tightness of the car under heavy rainfall.

  • Tire Testing on a Turning Test Circle

    The braking performance and the minimum turning diameter during a turn are tested.

  • Driving Test on Belgian Roads

    Ride and driving performance are tested on demanding road surfaces.

  • Desert Driving Test

    The car is put to the test on a proving ground in the Mojave Desert in California to test performance and robustness in extremely harsh conditions.

STEP4. Production

The car is mass-produced.

  • Casting

    A manufacturing process by which a liquid material is usually poured into a mold containing a hollow cavity of the desired shape, such as an engine cylinder block

  • Pressing

    The first process of manufacturing a car in which a metal plate is pressed vertically under high pressure into the desired panel

  • Engine Assembly

    A process by which an engine is assembled through machining and parts assembly

  • Body Assembly

    Panels made through pressing are assembled and welded into the shape of the car. A high level of precision and safety are required at this stage.

  • Painting

    Painting is required to protect car materials from corrosion, improve the exterior and ensure distinctiveness.

  • Assembly

    Parts are mounted on the inside and outside of the painted body, mechanical components are assembled, with the addition of the electronics, wiring and piping.

  • Inspection

    The car completed after outfitting is inspected for water tightness and functional integrity to ensure performance and safety.

STEP5. Road Driving Test

The car's quality is tested on the road.