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After the initial design of the car is finished, usually one of the longest periods in the overall process of producing a new car is the time between testing the first prototype cars until the last pre-production version is finished. This was the same case with the NT1. After we successfully finished the design stage we started to partially test the first prototype cars; these cars featured mostly parts specially manufactured using a special “fast prototyping” technique to give an idea about the look and fit. These prototype parts would not do for providing any accurate performance feedback. As soon as the first moulds were finished, the original moulded parts (which were then injected) were exchanged with the prototype parts on the car, allowing us to do enhanced testing of the real parts. To be able to do some serious testing, of course, we had to adjust the schedule and to work first of all on the moulds for suspension parts (the most critical parts) and then start the first real testing.

Click here for full XRAY Column #7 - Developing and Designing the NT1 - Part 2