Recently complex geometry and detailed Finite Element (FE) models have been used to capture the true behaviour of the structures for crashworthiness. Such model complexity, detailed FE model, high non-linearity of crash cases and high number of design variables for crashworthiness optimisation add to the required computational effort. Hence, engineering optimisation problems are currently highly restricted in exploring the entire design space and including the desired number of design parameters. Hence it is advantageous to reduce the computational effort to fully explore the design alternatives and also to study even more complex and computationally expensive problems. This thesis presents an efficient robust shape optimisation approach via the use of physical surrogate models, i.e. sub-models and models derived for the Equivalent Static Loads Method (ESLM). The classical simultaneous robust design optimisation (RDO) approach (where robustness analysis of each design is assessed) is modified to make use of the physical surrogate models. In the proposed RDO approach, design optimisations are made using sub-models and robustness analyses are made using either non-linear dynamic analysis or ESLM. The general idea is to approximate the robustness of designs at the start of the optimisation (using ESLM) and use accurate robustness evaluations (via non-linear dynamic analysis) towards the end of the optimisation where the optimisation has already found interesting regions of the design space. The approach is validated on crashworthiness design cases.

Abstract When we paint a nebulous future of tomorrow based on the research dictated by the available resources, we see a marathon run for the future that instigates new opportunities for the automotive industry with additive manufacturing. Cars of today are a product of subtractive manufacturing; but in future 3D printing would empower us to define a novel architecture that provokes the construction of the interior, exterior and the powertrain in one piece allowing us to celebrate the marriage between all three key components. Project UNO, meaning - ‘one’, exhibits this new architecture through a semi-autonomous concept that exaggerates the feeling of sportiness with a suspended cabin. In the autonomous mode the cabin moves around in the boundary of the exterior to enhance the g-forces by thrusting the cabin forward while accelerating, backward while braking and tilting while cornering. Therefore, the sporty nature of the design can be celebrated actively in both modes. Inspiration and Method The process was cut up into two palpable routes. The former dealt with a system level approach where the present cardinal building blocks of automotive manufacturing were rearranged with the new cues derived from additive manufacturing techniques to render a new system level solution. The later was aimed at advocating a tangible solution that best delineated this idea. Ten radical themes were generated that helped showcase the marriage between the three key components - exterior, interior and powertrain. The final theme was inspired by the analogy of an egg where the yolk moves freely within the egg white. This metaphor was then applied to the cabin experience in the autonomous mode. The occupant in the manual driven mode can cherish the full potential of the car to procure a sporty experience outside the city. While in the city, the autonomous mode seizes control and instigates the movement of the cabin within the perimeter of the exterior to amplify the g-forces by thrusting the cabin forward while accelerating, backwards while braking and tilting it while cornering. Result Concept UNO celebrates the marriage between the exterior, the interior and the powertrain that best encapsulates the process of additive manufacturing where cars would be grown and not assembled. The interior tub is reposed inside the exterior shell with the aid of six mechanical joints and is not adhered to the floor of the car. The gap around the cabin exaggerates the feel of a floating island that can shift freely. The cabin is composed of smart glass which renders opaque when an electric current is passed through it and turns transparent when the car is parked gravitating people to yield a glimpse of the interior. The bottom of the cabin is reflected by the gloss finish of the chassis unit that amplifies the floating feeling. A warm white was used to grant the concept a more puristic look while making it seem warm and friendly. The idea was then showcased through a 1:4 scale model printed in one piece using a Selective Laser Sintering (SLM) technique.

The topic of the project has been about the future of luxury mobility and how the brand Rolls-Royce could evolve alongthe technological advancements until the year 2038. As luxury is changing from being about possession to the experience of luxury, the goal was to design a vehicle that could support both new internal and external experiences about the vehicle. The identified obstacle that could limit the scope of new experi- ences in an autonomous vehicle is motion sickness. As cities grow and technology develops the future cities are crowded so personal space, and privacy is being limited.During the process, the tools used varied from form explora- tion through sketching, concept principle testing and finalization in 3d software as well as visualization tools to communicate the proposed solutions. Working out of the Rolls-Royce designstudio provided brand insight but also expertise in the field of color & materials as well as advice on engineering solutions from the design team.The result Rolls-Royce Luxe Nomad is a vehicle for exploring the world outside the urban areas. Going far and beyond in search of new and unique experiences but also making the trip there as enjoyable as possible. The concept provides a solution inspired by high-speed trains that could limit those effects. Through understanding the future customers need of privacy a method of controlling the amount of insight was developed to enhance the user experience and giving them an increased sense of control of their space.

Cars have been around for over a century and have grown to become an essential part of society with an increasing number of different models being sold and developed each year. Car manufacturers steadily expand the offered product portfolio and invent new market niches constantly. Often, this is not done to meet the customers’ expectations but rather to match and rival a competitor’s model lineup. The increase in model variety results in a significant increase in the complexity of production and manufacturing, more difficult and demanding work surrounding employees, and massive negative impacts on the environment. Not only are cars unsustainable in the way they are used, but also in the way they are produced. For a more sustainable future of and with cars to be possible, this practice of product portfolio expansion needs to be critically analyzed. It is, in my eyes, additionally necessary to evaluate the essence of the car industry, the car itself, and to re-think what defines a car. This paper critically analyzes the car industry and the production and development of cars, and it proposes an alternative to standard car design based on the idea and ability of speculative and critical design to highlight issues of today. The proposed concept is a speculative design alternative to car design, aiming to put sustainability and the customers back into the focus of car development, and discover what is possible, rather than probable, in the future of cars. The proposed concept aims at changing the understanding of cars and turns the car from being fixed and immutable into alterable and changeable objects, depending on the use-case and user. By analyzing manufacturing procedures and future trends, and interviewing experts from various disciplines, insights are used to evaluate the proposed alternative.

This research project was conducted to fulfill a Master of design specialising in Transport Design, at Massey University’s Auckland School of Design. It was aimed to create a new visual identity for Hyundai Motors by designing a car model forecasting and utilising methods pertinent to Hyundai Motors. Simultaneously the designed car model focuses on specifically accommodating the needs of surfers. The whole philosophy behind this particular model involves three important elements of Visual Identity as pointed out by Warell; recognition, comprehension and association. As a result, in each stage of the design process, the model was designed and amended continuously to incorporate these three issues to create a design for Hyundai that targeted the surfing market. This research sets out a departure point for designing differentiated vehicle concepts for Hyundai by targeting a niche market. The Exodus was designed for a particular demographic and a subculture. The targeted market began with participants of Extreme Sports such as snowboarding, windsurfing, and surfing, but was narrowed down to surfers, because they had specific requirements that were not well catered via by existing vehicles. These requirements also translated into specific design features that allowed the development of a strongly differentiate of vehicle concept. In this way the Exodus represents an example of how specific and user needs can drive differentiated design in both a practical and visually expressive way. This process was facilitated by way of three major research stages. Firstly, a field trip to Piha, one of Auckland’s most popular surfing beaches was conducted in order to find out more about surfing culture and as a general means of vehicle observation. Secondly, informed interviews were conducted in order to gather qualitative information to generate specific user requirements and inform design development that would meet the needs of surfers. Existing car designs types were analysed to extract any design features and attributes suitable for surfers. Thirdly, a comparative analysis of two established vehicle brands, alongside Hyundai was undertaken in order to reveal the weaknesses of Hyundai’s visual identity. This phase then culminated in a research model specifically aimed at creating a new design image for them. Based on requirements developed using the above methods, the design were developed through an interactive process of sketching, modeling and critique. The aim was to create a car with an advanced design that met the functional needs of the surfing market. The main focus was to create a specific, differentiated brand image based on association, comprehension and recognition for the Hyundai.

This diploma thesis deals with the design of the bodywork of a weekend sports car, based on the current Sigma TN vehicle, in order for better appearance and extended usability. The goal is accomplished by a new dynamic exterior design. Where the usability issue is solved by a modular roof system and luggage compartment. This work provides a new perspective on the concept and design of cars designed primarily for leisure driving.

Volvo Trucks: A Trucker's Pride   The North American trucking industry is in decline. By 2014, the United States is projected to be short 110,000 drivers (Wikipedia). The hardest hit segment is the long-haul sector, due to the difficult lifestyle of the long-haul trucker. Drivers experience long periods of time away from home, mediocre pay, and “miserable” working conditions. In order to revive the struggling industry and refresh the lifeblood of our civilization, the long-haul trucker lifestyle must be made more appealing. This project is a study into how to make the North American Long-Haul trucker lifestyle appealing to future trucker generations through both interior and exterior design.   In-depth research found that emotional needs of American long-haul truckers are not being met.  Emotional needs are directly linked to the concept of “quality of life”. Therefore, increasing the trucker’s quality of life would help truckers meet their emotional needs and thus help revive the North American trucking industry. Through interviews and questionnaires, pride was determined to be the key emotional need of the American Trucker. These interviews revealed that the best method to appeal to this key emotional need was to rethink the exterior form. It was decided that a design sculpture should be used to illustrate the concept of emotionally appealing transportation. For the interior design, research showed that a trucker’s fundamental human needs were not being met aboard the truck. Expanding the living space on-board and providing truckers access to their basic human needs allow people to truly live life on the road.   The Volvo Vision Long-Haul (VLH) helps future truckers take pride in themselves and their lifestyles. Pride comes from the aesthetics of assertive strength and the confident stance of the vehicle. A higher seating position gives drivers a commanding view of the road and the use of noble materials helps drivers feel they live in a quality environment. Onboard, the Volvo VLH maximizes interior space, providing enough room for a trucker to live life on the road.  To meet basic human needs, the truck has a shower and toilet onboard, along with a kitchen complete with stove and sink. The lofted bedroom offers feelings of exclusivity and expands upward when the vehicle is parked. This unique expanding space is accessed via a spiral staircase, which stores neatly away when not in use. The Volvo VLH meets the emotional needs of the American long-haul trucker, making the lifestyle appealing to future generations.