Crafting the Future: The Art of Clay Modeling in Automotive Design

In the Škoda Design department, skilled craftsmen are transforming innovative automotive concepts into tangible clay models, showcasing the physical form of future vehicles. This intricate process, which combines traditional craftsmanship with modern technology, is fundamental to Škoda's design philosophy. According to Martin Bogner, Head of Design Modelling and Digitalization at Škoda Auto, "Our design process has undergone a major digital transformation, allowing us to rapidly and efficiently explore various design directions for our future cars. However, we still rely on physical models to validate digital concepts and fine-tune details, ensuring the highest level of design quality."

The creation of a clay model begins with a basic skeleton constructed by the Technical Development department, designed according to specifications provided by the design team. The modelers use a special type of malleable clay that has been an industry standard for decades due to its ease of use and precision. Mick Allbutt, a modeler at Škoda, explains the clay application process: "Typically, we apply about a 4-cm layer of clay to the model, although this varies depending on the specific design and location."

The preparation and application of the clay is a labor-intensive process. Approximately two tonnes of clay can be utilized for a single model, and the clay must be heated to 60°C before application to ensure optimal malleability. The initial layer is applied in stages, requiring about two hours for six modelers to cover the skeleton with a 10 mm layer of clay. Subsequent layers are added as the model cools and hardens, which can take overnight to ensure structural integrity before further refinement begins.

Once the clay has set, the milling process commences. This involves using digital data to guide a milling machine that shapes the model with high precision. František Hladík, a technician involved in the milling process, notes, "Milling half of the car can easily take 20 hours, which is why we often let the machine run overnight." The milling machine handles about 95% of the model’s surface, but there are areas that require manual refinement. Modelers employ traditional tools such as scrapers, paddles, and knives to achieve the desired contours and details.

The versatility of clay allows modelers to make modifications quickly. Andy Settle, another modeler, states, "Altering a single design detail might only take a few hours. Our most important tools are our eyes and hands, which allow us to achieve the precision needed for high-quality designs."

As models progress, specialists work on individual insert parts, ensuring that each component is meticulously crafted. While 3D printing technology aids in the creation of base shapes, many details are manually refined to meet the designers' standards. Dušan Stejskal, a modeler, emphasizes the collaborative effort involved: "Even a simple air vent is actually a small puzzle of multiple pieces."

Moreover, the Škoda Design department features an in-house paint shop where various finishes are applied to model components. The painting process, particularly for intricate parts like headlamps, is done manually, requiring skilled artisans to mix colors by eye and achieve the desired aesthetic.

The fusion of digital tools and traditional techniques exemplifies Škoda's commitment to quality and innovation in automotive design. As the models are completed, they not only serve as prototypes for future cars but are also sometimes displayed at the Škoda Museum, celebrating the craftsmanship and creativity that go into each vehicle. As the automotive industry continues to evolve, the importance of balancing digital advancements with traditional methods remains a cornerstone of Škoda's design philosophy.