Application of advanced car design methodologies and innovative simulation systems for the development of new low-environmental-impact vehicles

The automotive industry is at a crossroads. For nearly a century, physical prototypes, particularly clay and foam models, have been the cornerstone of the design process. While these models offer invaluable insights into aesthetics and functionality, their creation is an incredibly resource-intensive and environmentally taxing process. Due to its advantages, this method is difficult to replace, despite its downsides, and the challenge now is to find a way to move forward without losing the benefits that physical prototypes can provide. This doctoral research explores how the automotive industry can reduce its reliance on these traditional, resource-heavy methods by embracing digital tools and technologies. The goal is not to replace the tactile experience of a physical prototype, but to complement it with advanced digital solutions that can make the design process faster, cleaner, and more sustainable. However, these tools can only perform at their full potential when integrated into a robust methodological framework that enables them to operate in harmony and amplifies their strengths. By utilizing the IDeS framework as the foundational structure and incorporating associated methods such as QFD and SDE, this research proposes innovative methodological approaches to achieve these objectives with a circular approach to the design process. These tools are combined with modeling, simulation, and optimization software to create a digital ecosystem that enhances whole the design process while minimizing environmental impact. By harnessing the power of these technologies, the study demonstrates that it's possible to create highly detailed, immersive digital prototypes that replicate the aesthetic and functional qualities of their physical counterparts, but without the associated waste, cost, and environmental harm. In doing so, this research lays the groundwork for a new approach to automotive design, one where sustainability isn’t an afterthought but is woven into the fabric of the creative process from the very beginning.