clay modelling at Ford Merkenich

An unsung car design essential under the microscope.

Get it while it’s… hard? Image: Fredaldous.co.uk

“We’ve simply never found anything better.”

Prosaic words in a modern world where the non-use of a computer or software could be deemed a disability – thank heavens then for a material still requiring skilled human hands to shape and form – clay. Used for eons, clay in the automotive industry requires chemical alterations. Natural clay requires baking to gain its strength and rigidity but which renders the product non-alterable. To allow for modelling complex curves or knife-sharp edges, natural clay contains added oils or waxes and in the early days a volume filler, (sulphur) to maintain its pliable attributes.

Delivered in blocks (or billets), once warmed through, the clay can then be applied to a rudimentary shaped wooden buck or wire armature in clumps, literally thrown on then hand kneaded to express a basic shape. Once air dried, this automotive modelling clay maintains its malleable state and allows the skilled human along with a variety of hands tools to Continue reading “Chavant and Di-NOC”

Every month that a project runs costs a car company money. In the ’80s a major car project could last 8 years, of which four was probably fully manned. These days the figure is 36 months but it could drop to 24. How?

There will be less of this in future. It´s a hand-modelled shape: ophelia.sdsu.edu

One aspect of the drive to cut development time is in rapid prototyping. This has been going on for quite some time. In 2006 it was normal practice to mill quick models of car interior trim prior to tooling so as to see how the form looked in three real dimensions. Non-visible parts have also been made quickly so as to speed production. Even CAD modelling itself is a time-saver (or can be) which is now taken for granted. Continue reading “Theme: Economy – Cost Cutting the Digital Way”