From Porches to Holdens, this is how new cars are made | finder.com.au

How is a new car made?

Read about the fascinating process involved in designing a new car.

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Have you ever wondered how a car manufacturer creates a new car? The amount of work that goes into the lengthy styling and design process is startling.

Step one: Business case/marketing study

The whole process of creating a new car can start up to a decade before the vehicle ever turns a wheel, let alone before commencing any design work. The actual design and production process typically takes between three and four years.

A new car starts as a business case or marketing study. The manufacturer’s analysts will determine future car industry trends, including the kind of cars that buyers will look for. They will also develop projections for the type of vehicles that will suit a motorist in five to ten years' time. Employees conduct feasibility studies and surveys to collect buyer feedback.

With a firm idea of the kind of car buyers want, engineers can then determine whether the new model will run on an all-new platform or whether the underlying mechanical architecture and engines can be shared with sister car models or companies. The underpinnings and engine options enable engineers to flesh out some solid dimensions that designers will need to work around.

At some stage, the team will write a brief and pass this on to car stylists in the design studio. The brief outlines some general requirements and points to be aware of.

Step two: Sketching / Drawing

Next, a group of car designers will start sketching, putting concepts onto paper. Through continual refinement, individual elements will evolve or be ditched altogether. Eventually, the designers turn the drawings into a digital rendering with more detail. The designers will work on several different perspectives and a finalised car design may take up to 1,000 sketches.

After the concepts are finished, the team presents them to decision-makers and stakeholders in the company. They may have to pitch their design against their colleague’s work, explaining how they arrived at the particular solution and why it answers the brief the most effectively.

Step three: Packaging

Remember that pesky business of using pre-developed engines and subframes? This stage may now require the stylist to revise their design and make numerous compromises for the sake of economy or engineering. Lots of interdepartmental workshops and assemblies take place between engineers, technicians and designers.

Step four: 3D modelling

Nowadays, the car design process is heavily computerised. Using a 3D CAD modelling program, the modellers convert the 2D renderings into three-dimensional data. To do this, modellers need a front, side and rear perspective profile and possibly a top-down view. The design team works directly with the modeller as they translate a design into 3D. The industry standard software for this is Autodesk Alias which is used by carmakers like Tesla.

Once the 3D model is complete, it is again showcased to a group of stakeholders. Nowadays, car companies will often use a power wall to show off the concept. The wall works like a giant screen where the 3D model is enlarged to 1:1 scale.

Step five: Clay modelling

Once given the go-ahead, the design process moves to the clay modelling stage. A steel or wooden support buck, which has dummy axles and wheels, is covered in an industrial plasticine-like material. Then, the 3D model data can be passed to a robotic carving tool, which rough cuts the clay form. Next, sculptors will go in with clay working tools and improvised scrapers to refine and polish the clay into shape. The clay buck may be 1:4 scale or full-size.

Designers will work with the sculptors, often employing tape as a simple way to lay out a new line or communicate a styling alteration. One long-time Ford clay modeller said he’d often come back from lunch to find tape applied all over the ceramic form indicating changes to be made.

Finally, the sculpting team works toward creating a frozen model, which is painted to look like the finalised and completed car. They look so real that the marketing department can use shots of these models in promotional material. These frozen models weigh upwards of 5,000kg!

Step six: Interior design

While the exterior of the car comes to fruition, a team of interior specialists works on designing the cabin. They use a similar methodology to the exterior team. They may create a life-size rig of the interior for evaluation purposes. The interior design team considers hundreds of fabrics and materials before they choose a selection of interior designs.

On modern cars, everything centres on the infotainment screen. The interior designers also need to work on developing an ergonomic and practical passenger compartment.

Step seven: Colours

Even paint colours are a product of countless hours of work and experimentation. The inspiration for a colour scheme could be taken from architectural, fashion or product design trends. The team can go through up to one hundred different paint colour combinations and 1,000 litres of paint. Once complete, a buyer will have around a dozen different colours to choose from.

Step eight: Engineering finalised and production commences

The last step is to get the car signed off for assembly and production. The full-scale clay model will be shown to upper management. Several working prototypes will be built. If it becomes evident that a particular body crease or styling line is difficult to manufacture, it can be adjusted right up to the last minute.

Once given the ultimate sign-off, a car designer can sit back, relax and then start work on their next project. It is an intense and exhaustive journey, supported by a workforce of hundreds of specialists and professionals.

Want to buy a new car?

It is astonishing to learn of the effort that goes into developing a new vehicle. In addition to an attractive and updated exterior, new car models benefit from several advanced automated safety features that will protect you and your passengers. Most new cars also perform exceptionally well in stringent crash tests and deliver sensible emission levels and fuel economy. Ultimately, purchasing a new car could save you money. Compare car loans here to get the best possible deal.

Compare some options to finance a new car

Data updated regularly
$
Name Product Interest Rate (p.a.) Comparison Rate (p.a.) Monthly Repayment View Details CTA
NRMA New Car Loan
From
4.99%
(fixed)
5.69%
You'll receive a fixed rate from 4.99% p.a.
Purchase a new or used car up to 2 years old and benefit from a fixed rate and no monthly fees. Pre-approval available within 5 business hours.
You'll receive a fixed rate from 4.99% p.a.
Purchase a new or used car up to 2 years old and benefit from a fixed rate and no monthly fees. Pre-approval available within 5 business hours.
Plenti Car Loan
From
4.89%
(fixed)
5.44%
You'll receive a fixed rate from 4.89% p.a.
Borrow up to $100,000 with a Plenti Car Loan and benefit from no early repayment or exit fees.
You'll receive a fixed rate from 4.89% p.a.
Borrow up to $100,000 with a Plenti Car Loan and benefit from no early repayment or exit fees.
Loans.com.au - New and Dealer Used Car Loan
From
4.67%
(fixed)
5.22%
You'll receive a fixed rate from 4.67% p.a. based on your risk profile
Finance a new car and benefit from features such as fast approval, no ongoing fees and an optional balloon payment. Settle the loan before 30 November 2021 and enter the draw to win a $1,000 fuel gift voucher. T&Cs apply.
You'll receive a fixed rate from 4.67% p.a. based on your risk profile
Finance a new car and benefit from features such as fast approval, no ongoing fees and an optional balloon payment. Settle the loan before 30 November 2021 and enter the draw to win a $1,000 fuel gift voucher. T&Cs apply.
IMB New Car Loan
4.99%
(fixed)
5.34%
You'll receive a fixed rate of 4.99% p.a.
A low minimum borrowing amount of $2,000 that you can use to purchase a new car or one that's up to two years old.
You'll receive a fixed rate of 4.99% p.a.
A low minimum borrowing amount of $2,000 that you can use to purchase a new car or one that's up to two years old.
Credit Concierge Car Loan
From
3.85%
(fixed)
4.91%
You'll receive a fixed rate of 3.85% p.a. with a comparison rate of 4.91% p.a.
Get access to over 20 providers to fund a new or used car.

You'll receive a fixed rate of 3.85% p.a. with a comparison rate of 4.91% p.a.
Get access to over 20 providers to fund a new or used car.

Wisr Secured Car Loan
From
4.74%
(fixed)
5.01%
You'll receive a personalised interest rate from 4.74% p.a. to 16.01% p.a. based on your risk profile
A flexible car loan from $5,000 - $63,000 with personalised rates and rewards for strong credit customers.

You'll receive a personalised interest rate from 4.74% p.a. to 16.01% p.a. based on your risk profile
A flexible car loan from $5,000 - $63,000 with personalised rates and rewards for strong credit customers.

NAB Personal Loan Unsecured Fixed
From
6.99%
(fixed)
7.91%
You'll receive a fixed rate between 6.99% p.a. and 18.99% p.a. ( 7.91% p.a. to 19.83% p.a. comparison rate) based on your risk profile
An unsecured loan up to $55,000 you can use for a range of purposes and pay off over up to 7 years. Note: Majority of customers will get the headline rate of 12.69% (13.56% comparison rate) or less. See Comparison rate warning in (i) above.
You'll receive a fixed rate between 6.99% p.a. and 18.99% p.a. ( 7.91% p.a. to 19.83% p.a. comparison rate) based on your risk profile
An unsecured loan up to $55,000 you can use for a range of purposes and pay off over up to 7 years. Note: Majority of customers will get the headline rate of 12.69% (13.56% comparison rate) or less. See Comparison rate warning in (i) above.
OurMoneyMarket Car Loan
From
5.35%
(fixed)
5.65%
You'll receive a fixed interest rate from 5.35% p.a. to 14.99% p.a. based on your risk profile.
Borrow between $2,001 and $75,000 to finance a new or used car up to 10 years.
You'll receive a fixed interest rate from 5.35% p.a. to 14.99% p.a. based on your risk profile.
Borrow between $2,001 and $75,000 to finance a new or used car up to 10 years.
CUA Secured Fixed Car Loan
6.79%
(fixed)
7.16%
You'll receive a fixed rate of 6.79% p.a.
A secured loan with a high maximum borrowing amount up to $100,000. Redraw facility and no monthly fees.
You'll receive a fixed rate of 6.79% p.a.
A secured loan with a high maximum borrowing amount up to $100,000. Redraw facility and no monthly fees.
Latitude Personal Loan (Secured)
From
5.99%
(fixed)
7.26%
You'll receive a fixed rate between 5.99% p.a. and 21.99% p.a. based on your risk profile
Lock in a competitive fixed rate when you offer security. Loan can be used for any purpose and repayments are flexible. You can check your interest rate before applying with no impact to your credit score.
You'll receive a fixed rate between 5.99% p.a. and 21.99% p.a. based on your risk profile
Lock in a competitive fixed rate when you offer security. Loan can be used for any purpose and repayments are flexible. You can check your interest rate before applying with no impact to your credit score.
Stratton Finance New Car Loan
From
3.85%
(fixed)
4.05%
You'll receive a fixed rate from 3.85% p.a. depending on the lender you are approved with
Apply for up to $250,000 and use cash or trade in a vehicle to use as a deposit. Optional balloon payment available.
You'll receive a fixed rate from 3.85% p.a. depending on the lender you are approved with
Apply for up to $250,000 and use cash or trade in a vehicle to use as a deposit. Optional balloon payment available.
SocietyOne Car Loan
From
6.99%
(fixed)
6.99%
You'll receive a fixed rate between 6.99% p.a. and 20.49% p.a. based on your risk profile
A loan from $5,000 to use for a range of purposes. Benefit from no ongoing fees and no early repayment fee.
You'll receive a fixed rate between 6.99% p.a. and 20.49% p.a. based on your risk profile
A loan from $5,000 to use for a range of purposes. Benefit from no ongoing fees and no early repayment fee.
RACV New Car Loans
From
4.99%
(fixed)
5.69%
You'll receive a fixed rate from 4.99% p.a.
A larger loan of $5,000 or more to help you buy a new or used car. 5-hour pre approval available and no ongoing fees.
You'll receive a fixed rate from 4.99% p.a.
A larger loan of $5,000 or more to help you buy a new or used car. 5-hour pre approval available and no ongoing fees.
NRMA Used Car Loan
From
6.49%
(fixed)
7.19%
You'll receive a fixed rate from 6.49% p.a.
Finance a used car with NRMA and benefit from a fixed rate term and no monthly fees. Pre-approval available within 5 business hours.
You'll receive a fixed rate from 6.49% p.a.
Finance a used car with NRMA and benefit from a fixed rate term and no monthly fees. Pre-approval available within 5 business hours.
Symple Loans Personal Loan
From
5.75%
(variable)
6.47%
You'll receive a personalised interest rate from 5.75% p.a. to 25.99% p.a. based on your risk profile
Borrow up to $50,000 to pay for what you need.
You'll receive a personalised interest rate from 5.75% p.a. to 25.99% p.a. based on your risk profile
Borrow up to $50,000 to pay for what you need.
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Compare up to 4 providers

Compare car insurance side-by-side and get quotes

Data updated regularly
Name Product Roadside Assistance Accidental Damage Storm Choice of Repairer Agreed or Market Value
Budget Direct Comprehensive
Optional
Optional
Agreed or Market
Finder's summary: Awarded the 2019 Finder Award for the Best Value Car Insurance, this policy offers solid coverage at a low cost plus you will get 15% discount on first year's premium when you take out a policy online. Budget Direct’s claims service has received a 4.2/5 based on nearly 5,000 customer reviews.

Who it might be good for: People who want a comprehensive policy without breaking the bank.
Bingle Comprehensive
Market
Finder's summary:Bingle consistently comes up as one of the cheaper insurers out there. It only covers the basics, so you don't get to choose your own repairer, you're not covered for personal items in the car and unless you add it as an option, you won't get a hire car if your car is stolen. But this keeps its premiums low.

Who it might be good for: Someone who wants a low-cost option that covers them for the basics.
Coles Comprehensive
Optional
Agreed or Market
Finder's summary: Coles have two-tiers of comprehensive car insurance to choose from. You'll earn double flybuys points at Coles supermarkets and you can get $10 off your Coles grocery bill every time you redeem 2,000 Flybuys points. If you're over 30, you can get roadside assistance free for a year.

Who it might be good for: Coles customers and Flybuys collectors.
Poncho Comprehensive
Agreed
Finder's summary: Poncho works like a monthly subscription – you pay monthly and can cancel and leave at any time. You can also list multiple cars and drivers under one policy, making it ideal for families and groups living together under one household.

Who it might be good for: People who want their car insurance month to month.
Woolworths Comprehensive
Optional
Agreed or Market
Finder's summary: Woolworths catches our eye due to some unique perks like a price-beat guarantee, where it'll beat any current comparable comprehensive renewal notice if you're over 25. You'll also get 10% off your grocery shop once a month and can add roadside assistance onto your policy for just $7.35 per month.

Who it might be good for: Woolworths shoppers and those that want to take advantage of its price-beat guarantee.
Qantas Comprehensive
Optional
Optional
Agreed or Market
Finder's summary: You'll be able to choose how comprehensive you want your cover to be with optional extras like choice of repairer and the option of agreed or market value. Plus earn Qantas Points for joining and paying your premium. Sign up by 2 May 2021, you can earn up to 30,000 Qantas Points (points awarded will be based on your premium). T&Cs and eligibility apply.
ahm Comprehensive
Optional
Both
Finder's summary: ahm comprehensive car insurance lets you choose higher excess to reduce your premiums plus you can get up to 15% off when you purchase a new car insurance policy. T&Cs apply. Additionally, their Fixed Kilometre Plan can save you up to 30% compared to their standard comprehensive cover.

Who it might be good for: People who drive less than 15,000 km per year.
Virgin Comprehensive
Optional
Optional
Agreed or Market
Finder's summary: Finalists for the 2019 Finder Awards for Best Value Car Insurance, Virgin Comprehensive provides a good level of cover for a decent price. Get 15% off on your first year’s premium when you purchase a new eligible comprehensive car insurance online. T&Cs Apply.
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Car Loan Offers

Important Information*
Logo for IMB New Car Loan
IMB New Car Loan

You'll receive a fixed rate of 4.99% p.a.
A low minimum borrowing amount of $2,000 that you can use to purchase a new car or one up to two years old.

Logo for Beyond Bank Low Rate Car Loan "Special Offer"
Beyond Bank Low Rate Car Loan "Special Offer"

You'll receive a fixed rate of 4.69% p.a.
Take advantage of a competitive rate, pre-approval and no early repayment fees when you finance a car under two years old.

Logo for RACV New Car Loans
RACV New Car Loans

You'll receive a fixed rate from 4.99% p.a.
A larger loan of $5,000 or more to help you buy a new or used car. 5-hour pre approval available and no ongoing fees.

Logo for NRMA New Car Loan
NRMA New Car Loan

You'll receive a fixed rate of 4.99% p.a.
Purchase a new or used car up to 2 years old and benefit from a fixed rate and no monthly fees. Pre-approval available within 5 business hours.

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