Volkswagen Group recently celebrated the 20th anniversary of its largest research facility outside Germany by unveiling a retrofitted 1962 VW Microbus, equipped with cutting-edge technologies that represent the future of automotive innovation. The project, led by the newly rebranded Innovation and Engineering Center California (IECC), focused on reducing weight while enhancing structural strength. Autodesk collaborated closely with the IECC team to apply generative design techniques, transforming key components of the vehicle.
“We’re merging a classic Volkswagen design with fresh ideas and innovative technologies from partners like Autodesk,†said Nikolai Reimer, executive director of IECC. “It’s a great opportunity to explore new possibilities and create a show car that reflects our vision for the future.â€
One of the main challenges in electric vehicle development is reducing weight to improve energy efficiency and increase range. This is where generative design comes into play, allowing engineers to create lighter, stronger parts without compromising performance.
The IECC team used generative design to completely rework the wheels of the 1962 Type 2 Microbus, resulting in an 18% weight reduction. The design process, which would typically take over a year, was completed in just a few months. “With generative design, we can create structures that human designers could never imagine,†said Andrew Morandi, senior product designer at Volkswagen. “Seeing the final rims arrive was like Christmas morning for the whole team.â€
Generative design was also applied to the steering wheel, rear seat support structure, and side mirror mounts. Erik Glaser, principal product designer, explained why the steering wheel was chosen: “It’s a primary touchpoint for the driver, and we wanted to showcase how strong and intricate these generatively designed parts can be.â€
Beyond weight savings, generative design streamlines workflows, enabling faster and more informed design decisions. “This project is just the beginning,†said Morandi. “In 10 to 15 years, I could see entire vehicle frames being generatively designed, which might revolutionize manufacturing.â€
Other companies, like General Motors and NASA, have also explored generative design. GM used it to develop lightweight seat brackets for future electric vehicles, while NASA created a generatively designed lander prototype for deep-space missions.
Reimer believes the full potential of generative design is still being discovered. “We’re only scratching the surface,†he said. “Combining human engineering with AI could lead to lighter, smarter, and more sustainable products. This will change not just what we build, but how we build it.â€
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