67-72 Development/Concept Photos Galore!

[nibulus]

Originally Posted by cleszkie

I'm not sure how the full-size conceptual models are made these days. I'm guessing its through the use of CAD and huge CNC-type machines to carve out the shapes. However, back in the day, these guys were frickin' artists! ...

Your guess is quite close to reality. At least for OEMs with larger volume, since the modeling machines are not that cheap (less surprising).

Here's an example of one. As you can see, details/changes are often modelled manually.

To reduce cost, one option is to use the frame of an existing vehicle, on which sort of "clay sheets" or thin "blocks" are mounted and then modelled either by machine or hand, depending on availability of 3D-data.

Another option is to make a completely new frame for the clay model, made of whatever material is reasonable. It could theoretically be made of wood, polymer, metal or whatever, depending on the purpose of the full-size model (exterior only, interior, engine bay etc.). Sometimes the models have to be driveable.

Originally Posted by cleszkie

... Shaping the models out of massive blocks of clay by hand. True craftsmanship.

I'd say those models in this thread weren't made of one massive clay block either. Not only to reduce cost.

Either way, it was and still is true craftmanship. And art. Funny to see that the challenges at the time (regarding cost, industrialization, marketing etc.) were pretty much the same as nowadays.

Speaking of challenges, it'd be really interesting to get some in-depth info about GM's product development / industrialization process back then.

[Keith Seymore]

Originally Posted by nibulus

Your guess is quite close to reality. At least for OEMs with larger volume, since the modeling machines are not that cheap (less surprising).

Here's an example of one. As you can see, details/changes are often modelled manually.

To reduce cost, one option is to use the frame of an existing vehicle, on which sort of "clay sheets" or thin "blocks" are mounted and then modelled either by machine or hand, depending on availability of 3D-data.

Another option is to make a completely new frame for the clay model, made of whatever material is reasonable. It could theoretically be made of wood, polymer, metal or whatever, depending on the purpose of the full-size model (exterior only, interior, engine bay etc.). Sometimes the models have to be driveable.



I'd say those models in this thread weren't made of one massive clay block either. Not only to reduce cost.

Either way, it was and still is true craftmanship. And art. Funny to see that the challenges at the time (regarding cost, industrialization, marketing etc.) were pretty much the same as nowadays.

The surface is created in the Design Studio via computer software (typically a modeling software that is "friendly" to creating smooth curves and blended surfaces).

The data can then be transferred to the clay modelers and the surface created in clay for review. This can be full size, half scale, quarter scale, as desired. You are also correct that it is not a "giant block of clay", but a layer of clay added over an "armature", that is, a structure of metal, wood and/or Styrofoam.

After there is agreement that the surface meets Studio expectations then it is sent over to engineering for evaluation, to make sure the panels can be formed and establish details like door cut lines, "B" surface details like what you see when you open the doors and such, material thickness and component packaging. Once that's done then the engineering team can start designing up the individual parts and details in earnest, in a different software that is more conducive to part detail and manufacturability.

It would be easy (...easier...) if this was just a straight flow through process but naturally it is an iterative process, as engineering learns that certain items won't work or can't be made. The Studio is also characterized by changing their mind or wanting to add content late in the game because they just saw the latest whiz bang thing or because they want to introduce the latest styling theme on the product just before it launches.

It is a constant game of give-and-take as a result of the creative tension between the two groups and their requisite personalities.

K

[Keith Seymore]

Originally Posted by nibulus

Speaking of challenges, it'd be really interesting to get some in-depth info about GM's product development / industrialization process back then.

This happens to be about Camaros but it would be relevant to other passenger car models and trucks as well. This is the best overview I've seen and was written by John Hinckley, who was on the production launch team at the time. He is pictured in the body drop photo, in the white shirt with his back to the camera.

K

http://www.camaros.org/assemblyprocess.shtml