Aerodynamics: key aspects of automotive exterior design.

The exterior parts of a car give it character, create atmosphere, and makes it sporty, elegant or urban. However, when designing these components, many factors have to be balanced, such as appearance, functionality, aerodynamics, and safety. The process of designing car exterior parts is fascinating and challenging. In this article, Karol Skrzypiec – Team Manager, Competence Centre Exterior at Endego, will take us through the key aspects and trends in car exterior design.

Exterior: what does it actually include?

The exterior of a car is defined as all those parts that do not affect the strength of the car but only serve an aesthetic purpose: mirrors, caps, grills, emblems, spoilers, bumpers, and many others. It is these parts that give vehicles their unique character and visually distinguish them from the competition. Thanks to them, manufacturers make cars that do not differ from each other in terms of interior design but  have a completely different character. The aerodynamic lines, for example, give vehicles a sporty flair, while the less dynamic, classic body design is ideal for city cars.

From clay model to real car

The design process starts with a clay model, which is then finely finished by artists. This is the stage where the first version of the car is created. Once the model has been refined, 3D scanners are used to create a point cloud, and stylists then work on the surface of the A-Class. This work is very precise and forms the basis for the designers’ decisions when building the car.

The materials prepared in this way are the starting point for the design process. The components that hold the structure together are detailed. In the first design phase, special attention is paid to pedestrian safety. The designers make sure that the elements of the structure are properly rounded – so as to minimise the risk of injury in the event of a collision with a pedestrian. The design undergoes tests to check that there are no sharp edges or bulges that could cause injury in a collision with a person.

An example of this adaptation of the car’s design to pedestrian safety standards is the Mercedes-Benz brand logo. The star that adorned the bonnet of every Mercedes was quickly integrated into the safety concept so as to protect pedestrians in the event of a collision. Since the early 1950s, it has been mounted on the universal joint so that, in the event of a collision with a pedestrian, the star deforms, absorbing the impact energy and reducing the risk of injury. Mercedes-Benz is now moving away from the concept of a protruding element on the bonnet in favour of an emblem on the grill, which is safer for pedestrians. Interestingly, the star was often stolen, making it one of the most frequently purchased Mercedes-Benz spare parts.

Key factors in the design of car exterior elements

• Safety

Pedestrian safety standards are one of the key considerations when designing car exteriors. Designers check that the surfaces of these elements comply with the standards and, if necessary, make the required adjustments.

• Manufacturing technology

Another important factor in the design of exterior components is the technology that will enable the part to be made effectively. Designers try to design parts in such a way that they can be made or plastic injection moulded. It is also important to keep the wall thickness of the parts constant to avoid visible defects and deformation. The elimination of suction is, in turn, an important part of the design process, ensuring that the final product is aesthetically pleasing and safe to use.

• Aerodynamics

Another important factor is aerodynamics. The exterior components of a car are designed to minimise drag and improve airflow around the vehicle. The use of optimal shapes and the smoothing of surfaces contribute to reducing noise, increasing performance, and lowering fuel consumption.

• Aesthetics

Aesthetics are also important. Designers strive to create exteriors that are visually appealing and fit with the overall style of the car. Aesthetics are an important factor in how a car is perceived by potential customers. The right design of exterior elements can attract attention and generate interest.

Challenges in the design of car exterior components

• Keeping weight as low as possible is one of the key challenges when designing the exterior parts of a car. For customers, it is important that components are as light as possible to reduce fuel consumption and emissions. Designers therefore seek to minimise the number of components and reduce wall thickness while maintaining durability.
• Keeping the number of components as low as possible – the number of components is crucial for manufacturers and the price of the vehicle: the fewer the components, the faster and cheaper the manufacturing process.
• Minimise the incidence of overmoulding and parting. Overmoulding and parting can cause surface defects that affect the aesthetics of the bumper. It is therefore important to limit their occurrence in the design, thus minimising the risk of errors.

How are companies dealing with these challenges?

• Wall thickness – the components are made of thin walls to reduce weight.
• Cut-outs in the covers – cut-outs in the covers make it possible to reduce the amount of material and, as a result, the weight of the bumper.
• Selecting materials of the right density – the use of mixes of materials with different densities allows the weight of the components to be adapted to the customer’s requirements.
• Minimisation of the number of components – combining several functions in a single component makes it possible to reduce the total number of vehicle components.
• Moulding technology – appropriate routing of the shape of the structure to avoid the formation of suctions and mould splits during pressure injection.

Trends in automotive exterior part design

Today’s automotive market is shaped by a number of trends influencing the design of car exteriors. Among the most important of these are:

• Electromobility – increased interest in electric cars is leading to changes in vehicle styling and the use of modern materials.
• New technologies – increasingly complex shapes and lighting elements are dictating the shape of bumpers, and technologies such as cameras are replacing traditional mirrors.
• Autonomous vehicles – as autonomous cars are developed, the number of sensors and communication elements between vehicles is increasing. This presents designers with new challenges in concealing these elements in an elegant way while maintaining a high level of car aesthetics.

Endego’s role in the design of external elements

The Endego team of experienced designers and professionals is first and foremost passionate about automobiles. Our love for cars drives us to constantly improve our skills and create exterior elements that meet the highest standards of quality and aesthetics.

Endego’s solutions combine innovation, aesthetics, and functionality in a minimum of time, resulting in elements that give cars their unique character. As a result, our customers are able to deliver vehicles faster and more efficiently than other manufacturers.

In designing car components, our priority is an innovative approach based on sound technical knowledge and extensive experience. Regardless of the scale of the project, we approach it with commitment and passion.

At Endego, we understand that the exterior components of a car are not just decoration, but also have an important utility role. Bumpers protect both the vehicle and pedestrians in the event of a collision, while spoilers improve aerodynamics, resulting in fuel efficiency and better stability at high speeds. Our solutions, therefore, combine beauty and functionality.

If you would like to know how we can support your company in designing car components, contact us today!