How Cars are Made

First, current trends and fashions are investigated.

Designing new vehicles takes at least one and a half years until production at a factory starts and can take as long as three to four years. The kinds of cars to make is decided while thinking about how society will change three to four years in the future and about trends and people's lifestyles and preferences.

After the new car is investigated, we prepare sketches so we can see what it looks like. Many different aspects of the design are considered such as the outside shape and the inside shape and color.

In the last step, the number of sketches is narrowed down, computers are used to make three-dimensional images, and actual size clay models are made to confirm every detail and complete the design.

Numerous tests such as: collision tests, high speed driving tests, rough road tests, crosswind tests, brake performance tests, low temperature tests, radio wave effects tests, wet road tests and driving tests in different regions around the world are made.

Collision Tests

The safety of vehicles is tested by colliding them to make sure that if a collision does occur the passengers inside will be safely protected.

High-Speed Driving Tests

Tests are conducted to make sure that the cars can drive safely on highways.

Rough Road Tests

Tests to make sure cars can drive safely even on rough surfaces are made.

Crosswind Tests

Cars are made sure that they can drive safely even when there are strong crosswinds.

Brake Performance Tests

Tests to make sure brakes work properly.

Low Temperature Tests

We check that cars will work properly even in cold regions

Radio Wave Effects Tests

Tests are conducted to make sure that radio waves don't affect the computers and other devices used in cars.

Wet Road Tests

We perform tests to make sure cars can drive, turn, and stop safely even on wet roads.

Driving Tests in Different Regions Around the World

We conduct tests around the world according to road and climate differences in different regions.

How the Body of a Car is Made

The steel sheets used in the car bodies are sent from the steel-making company to the factory in big rolls. The steel is made flat before it is used.

The steel sheet is cut according to the size of the part and then is bent and cut in a stamping machine to make parts such as car doors, roofs, and hoods. The stamped parts are inspected and then transported to the welding process.

Steel sheets are transported to the factory in big rolls.

The stamping process

A stamped part

Welding is performed mostly by robots. Stamped parts are heated using electricity and melted at specific points to be joined together to form the cars. The welded parts are inspected and then transported to the painting process.

Each car is painted a different colour at the painting process according to the customer's order. Before painting, a high-pressure shower removes dirt and oil from the car.

Cars are painted three times-an undercoat, a middle coat, and a topcoat.

Undercoat: To apply the undercoat, the car is passed through a pool of paint that has electricity passing through it to prevent rusting.

Middle coat: A robot evenly sprays on a grey paint to help the topcoat keep its colour and to make the car surface smooth.

Topcoat: A robot sprays on the final vehicle colour from different angles to make an even finish.

After the painting is finished, the paint is allowed to dry and is then inspected.

After all these are done the engine is made and fitted into the new car. It is then sold to car dealers.