The Automotive from Product Design Perspective
The Automotive from Product Design Perspective
Summary
Automotive product design follows a structured, systematic process, commencing with a thorough analysis of customer needs that are subsequently translated into specific, measurable technical and functional requirements. This multi-step framework, which guides engineers from initial conceptualization through detailed design, testing, and final production, critically balances customer desires with manufacturing realities and various regulatory constraints. Furthermore, modern automotive design is increasingly adopting circular economy principles, shifting away from a traditional “take-make-dispose” model to prioritize the entire product life cycle for enhanced sustainability, resource efficiency, and the generation of new economic opportunities through strategies like remanufacturing and material recovery.
Learning Objectives
Explain automotive engineering design principles and applications
Analyze the automotive design process from requirements to production
Convert customer needs into technical specifications
Balance customer demands, manufacturing limits, and regulations
Apply structured design methods to automotive challenges
Explain product life cycle impacts on automotive design
Apply circular economy principles for sustainability
Assess how design affects manufacturing, cost, and sustainability
Introduction to Design and Engineering
What is engineering?
Engineering is the field of practice, profession and art that relates to the development, acquisition and application of technical scientific and mathematical knowledge. It is about the understanding, design, development, invention, innovation and the use of materials, machines, structures, systems and processes for specific purposes (UNESCO 2025).
What is design?
A process that translates requirements into well-defined specifications for a product, system, or process. In this course, our focus will be exclusively on automotive product design.
How to Design? The Design Steps
A proper design follows a structured process. This process as shown in Figure 1.1 always starts from customer needs and ends with a final product. Each step is described briefly below.
Flow diagram of the engineering design process.
Customer Requirements Analysis
This initial phase involves gathering and documenting all needs, expectations, and constraints from stakeholders. This involves interviews, market research, and feasibility studies to understand the problem space. The output is a comprehensive requirements document that serves as the foundation for all subsequent design work.
In vehicle design, customer requirements can be categorized as:
Practical & Performance: Cost, economy, weight, handling, speed, flexibility, comfort, durability, off-road capability, emissions, towing capacity, loading capacity, maneuverability, range, power, safety/crashworthiness.
Space & Capacity: Size, interior space, cargo volume, number of passengers.
Aesthetic & Customization: Image, trim level, colors, customizing potential, aftermarket component availability, brand identity.
User Experience: Security, noise/vibration/harshness (NVH), command-of-the-road seating, easy ingress/egress, sound.
Balancing Customer Desires with Manufacturing Reality
Automotive design must reconcile what customers desire with what manufacturers can realistically produce within regulatory boundaries. Achieving this balance is essential for creating viable, market-ready vehicles.
Manufacturing Limitations
Cost structures and budget constraints
Product portfolio strategy and brand positioning
Platform commonality and shared architectures
Derivative development capabilities
Production scale and volume requirements
Supply chain availability and logistics
Regulatory Requirements
Occupant protection standards (FMVSS, Euro NCAP)
Pedestrian safety protocols
Emission compliance (Euro 6, EPA standards)
Sustainable production mandates
Fuel economy regulations (CAFE, EU CO\(_2\) standards)
Successful vehicle development navigates these constraints while delivering compelling products. The best designs satisfy user expectations without exceeding practical manufacturing or regulatory boundaries.
Functional Requirements Development
The customer requirements are translated into specific, measurable technical specifications. This phase defines what the product must do (functional requirements) and how well it must perform (performance requirements). Requirements are prioritized and validated to ensure they are achievable within project constraints.
Requirements Translation Process:
Need Identification: What does the customer actually require?
Function Definition: How will the vehicle fulfill this need?
Performance Metrics: What measurable criteria define success?
Priority Ranking: Which requirements are critical vs. desirable?
For vehicles, functional requirements may include acceleration performance, braking distances, fuel consumption, handling characteristics, and crash safety ratings. Engineers must balance these factors with regulatory standards, ensuring compliance with industry requirements like Euro NCAP or EPA emissions regulations.
Example Translation:
Customer Need: “I need a safe family car”
Functional Requirements:
5-star safety rating capability
Minimum 5 seating positions
Child seat accommodation (ISOFIX/LATCH)
Advanced driver assistance systems (AEB, LKA)
Crash energy absorption structure
Conceptual Design
Engineers generate multiple design concepts through brainstorming and ideation sessions. Each concept is evaluated against the functional requirements using methods like Pugh matrices or weighted decision matrices (Hatamura 2006). The most promising concepts are selected for further development, often represented through sketches or basic CAD models.
During vehicle design, this step involves:
Selecting body style (sedan, SUV, hatchback, coupe, etc.)
Choosing drivetrain layout (front-wheel drive, rear-wheel drive, all-wheel drive)
Preliminary aerodynamic considerations
Material selection strategies for weight reduction while maintaining structural integrity
Platform architecture decisions
Powertrain type selection (ICE, hybrid, electric)
Preliminary Design
The selected concepts are developed into more detailed designs. Engineers create system architectures, perform initial calculations, and identify key components. Prototypes may be built to test critical functions. This phase often reveals necessary adjustments to both the design and requirements.
For vehicles, preliminary design includes:
Defining the powertrain specifications (internal combustion, hybrid, or fully electric)
Suspension geometry and kinematics design
Steering mechanisms and control systems
Basic electronic systems architecture
Vehicle packaging and space allocation
Preliminary structural design and load paths
Engineers may conduct wind tunnel testing and/or CFD simulations to optimize aerodynamics for fuel efficiency and performance. Initial crash simulation studies help validate safety concepts.
Detailed Design
Every aspect of the product is specified in precise detail. Complete 3D CAD models are developed, along with engineering drawings, material specifications, and manufacturing instructions. Simulations (FEA, CFD) are run to verify performance under expected operating conditions.
Vehicle detailed design includes the design of subsystems and components such as:
Chassis design and structural optimization
Powertrain integration and mounting systems
Electronic control unit (ECU) programming and calibration
Optimal tire sizes and wheel specifications
Suspension component design and tuning
Crash-impact zones through finite element analysis (FEA) simulations
Body panel design and manufacturing feasibility
Interior ergonomics and human factors engineering
Final Design and Testing
The completed design undergoes rigorous verification and validation testing. Prototypes are built and subjected to performance tests, environmental tests, and reliability tests. Test results may lead to final design refinements before production tooling begins.
For automobiles, this phase includes:
Crash tests (frontal, side, rollover, pedestrian impact)
Fuel efficiency validation and emissions certification
Long-term durability assessments and accelerated aging
Environmental testing (cold weather, extreme heat, high altitude, humidity)
NVH (noise, vibration, harshness) validation
Performance validation (acceleration, braking, handling)
Electromagnetic compatibility (EMC) testing
Prototypes are tested in different environmental conditions to verify real-world performance before mass production approval.
Production
The approved design moves into manufacturing. Production processes are optimized, quality control systems are implemented, and initial production runs are closely monitored. Feedback from early production often leads to minor refinements in both the product and manufacturing process.
In vehicle production:
Automated robotic assembly lines ensure consistency and precision
Quality control inspections identify defects before vehicles reach customers
Statistical process control monitors manufacturing variation
Endurance testing ensures mechanical reliability
Regulatory agencies certify safety and emissions compliance
Supply chain management ensures component quality and delivery
Continuous improvement processes optimize efficiency and quality
Product Life Cycle and the Circular Economy
The linear design process depicted in Figure 1.1 focuses primarily on the design stage, but modern automotive design extends beyond this, considering the entire product life cycle (PLC). Traditionally, products followed a linear “take-make-dispose” model, leading to significant resource and energy waste. In contrast, the circular economy adopts a “cradle-to-grave-and-back-again” approach, prioritizing resource efficiency by designing products for longevity, reuse, and regeneration.
Understanding Product Life Cycle
The PLC, illustrated in Figure 1.2, describes the stages a product undergoes—from development and introduction to growth, maturity, and eventual decline or phase-out. Key phases include market research, design, production, marketing, and discontinuation. Businesses leverage PLC strategies to optimize pricing, promotion, and innovation while adapting to competition and technological shifts.
The generic life cycle of products .
In manufacturing, particularly in the automotive industry, effective PLC management ensures cost efficiency and sustainability, with increasing emphasis on circular economy principles such as recycling and remanufacturing (Autoprotoway 2025).
Circular Economy Principles in Automotive Design
Materials are kept in circulation through strategies like remanufacturing, refurbishment, and recycling, minimizing environmental impact and creating closed-loop systems. The automotive industry exemplifies this shift through innovative design and business models:
Design for Circularity:
Vehicles engineered for disassembly with modular components
Design facilitates repair, upgrades, and repurposing
Material selection prioritizes recyclability and renewable sources
Standardized fasteners and connection methods for easy disassembly
Material Integration:
Integration of recycled materials (reclaimed plastics and metals)
Bio-based materials and sustainable alternatives
Reduced material variety to simplify recycling processes
Material passports for tracking component composition
End-of-Life Management:
Systematic dismantling to recover valuable parts and materials
Component remanufacturing and refurbishment programs
Material sorting and recycling optimization
Hazardous material safe disposal protocols
Business Model Innovation:
Car-sharing and mobility-as-a-service models
Leasing models that extend product utility
Component-as-a-service offerings
Take-back programs for end-of-life vehicles
Sustainability Impact
By embedding circular economy practices, the automotive sector not only reduces waste but also strengthens sustainability across the entire value chain—from raw material sourcing to end-of-life recovery. This approach:
Reduces demand for virgin materials and energy consumption
Minimizes waste generation and landfill burden
Creates new revenue streams through material recovery
Enhances brand reputation and regulatory compliance
Drives innovation in design and manufacturing processes
The integration of circular economy principles represents a fundamental shift in how the automotive industry approaches design, manufacturing, and business models, creating more sustainable and economically viable solutions for the future.
References
Autoprotoway. 2025. “Automotive Product Development: Stages, Case and Consideration.” https://autoprotoway.com/automotive-product-development/.
Hatamura, Yotaro. 2006. Decision-Making in Engineering Design: Theory and Practice. Springer. https://link.springer.com/book/10.1007/1-84628-261-6.
UNESCO. 2025. “Engineering | UNESCO.” https://www.unesco.org/en/basic-sciences-engineering/engineering.