Design evolution: the computer takes centre stage

During the development of the sensational new Mercedes-Benz A-Class, which will soon be brightening up our roads, the Mercedes-Benz design team adopted a state-of-the-art approach, with the computer functioning as a key design tool from start to finish. The only time that the design process followed traditional practices in any way was in its infant phase, when the designers used free-hand sketches to explore the full scope of possibilities presented to them by the task at hand. However, even at this early stage, some stylists did without paper, preferring instead to sketch directly on the monitor using a graphics tablet.

By so doing, they chose the approach which was eventually used for all of the draft designs which were initially selected: their lines and curves were converted into a dataset which enabled the design concept to be illustrated in three-dimensional form. In the CAD Pool, the designers were then able to harness the powers of digital technology to the full: any alterations were transferred to large wall monitors where they were able to make any necessary refinements instantly, using drawing strokes or by taping over.

By adopting this method, it was possible to produce variants which already tallied with the engineering and dimensional specifications to a high degree with tremendous precision and far quicker than ever before. The selection was narrowed down to nine designs which were then all subject to a critical examination on the "Powerwall". High-performance systems with colossal computational power are able to project the models onto the Powerwall, which measures the width and height of one room, ena-bling the designers to scrutinise and analyse them from every conceivable angle.

The intensive work carried out at the Powerwall was finally rewarded by a highly accurate appraisal of the different designs. The team never intended, however, to make final decisions based on computer-generated models alone. After whittling down the number of designs from nine to just six, the modelling specialists took over and turned the computerised versions into a solid clay version with tactile qualities. This meant that the designers were now able to put the final touches to the contours of the wings and to the headlamp transition lines.

From these six models, the design chief together with the Board of Management short listed three which were produced in a life-size 1 : 1 format. Each and every modification which was made at this stage was transferred directly into the dataset by the digitalisation specialists, to both keep the data constantly up to date, and to make the definitive dataset available to other specialist departments, such as body-work design, for comparison purposes. As a result of this method, it was possible to attain both compelling bodystyling as well as an advanced degree of product maturity at a very early stage.

Again and again, the selected draft designs were projected onto the Powerwall where they assumed the lead roles in scenes based closely on everyday life, such as driving in traffic or parking alongside other models of car. After all, the design of the new A-Class should still single it out as being thrilling and full of self-assurance when its owners are going about their day-to-day business.

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