Nearly 2000 pre-series prototypes have been built in our workshop since 1968, not to mention hundreds of show cars and the numerous prototype elements and units we have prepared and used to assess the shapes created by the design process.
Nowadays, development activities are supported by verification and validation methods based on virtual simulations with an accuracy of close to 95%. Checks on physical objects are nevertheless still important and the major manufacturers still need us to develop prototypes that are representative of production in significant quantities and with ultra-high levels of precision to ensure that all design parameters are complied with before they begin to build the expensive equipment required for production. The Italdesign Giugiaro prototype construction department is able to set-up moving prototypes that are complete in every detail. Performing these checks and adding any corrections to the design enables us to validate the engineering calculation and determine the final areas on which the dies that will be constructed for use in standard production are based. For this activity we use various procedures with dies that can produce a few units or a series of parts, depending on our requirements. In this department too, a spirit of craftsmanship goes hand-in-hand with technology: the work may be carried out by hand with the use of beating and panel-beating models for quantities up to 3 units. Parts produced in this way are of extremely high quality, and the parts mass-produced with the final equipment will be of the same quality. The presswork is carried out with presses, whereas the trimming and cutting is normally done by laser cutting robots. Product dimensional control and certification are an essential part of the supply and development process for turnkey products. Because changing automotive market safety and quality requirements have significantly increased the need to carry out very extensive dimensional controls from the initial prototype stages, sophisticated mechanical and optical control systems check the dimensions at each stage. This activity, carried out by extremely skilled staff supported by top-level equipment, acts as a guarantee for customers and an essential tool for achieving the excellent results that underpin Italdesign Giugiaro's quality policy. At the end, the result is checked both on the road and by simulation with the aim of achieving official type approval in the markets where the vehicle is sold.