GM Vice Chairman Bob Lutz has recently confirmed the 2010 deadline for the production version of the Chevrolet Volt.

Below we report the information released by GM in the past weeks about the development process of the production version of the car, related to the aerodynamics improvement process and the new design facility.

We also report a set of images from the design development process of the Chevrolet Volt Concept. The images are taken from GM Advanced Design Director Bob Boniface's presentation at AutoWeek Design Forum 2007 (click here to watch the video).

Chevrolet Volt Concept - Preliminary design studies

Chevrolet Volt Concept - Clay modeling process

Chevrolet Volt - aerodynamics development

According to GM, "aerodynamic improvement is a critical step in meeting the range targets necessary for moving the vehicle to a final production decision."

Aerodynamic drag accounts for approximately 20 percent of the energy consumed in an average vehicle, directly impacting vehicle fuel efficiency.

Aerodynamics development begins with a 1/3-scale model where basic shape and major features are defined. The model includes a highly detailed underbody and engine compartment. Radiator and under hood cooling flow is developed with computational fluid dynamic models.

Simultaneously, computation development takes place to determine aerodynamic drag of design alternatives. Development continues with full-scale models, where shape is refined and optimised for low wind noise. The development process concludes with a vehicle prototype validation of the math-based analysis and physical testing.

“We have achieved a vehicle that had a coefficient of drag that is more than 30% lower in drag than the original concept,” said Ed Welburn.

GM E-Flex Systems Design Studio

GM has announced the opening of a new studio dedicated to the development of electrically-driven vehicles. The facility is located within GM’s Advanced Design Center. The Chevrolet Volt, GM’s electric plug-in vehicle, will be the first vehicle designed in the new studio.

GM’s new E-Flex Systems Design Studio will develop a variety of vehicles using the E-flex propulsion system, starting with the production version of the Chevrolet Volt. It is the only studio on the planet specifically designated to designing a wide variety of electric plug-in vehicles with a range extender.

“As soon as the project kicked off, I knew we needed a dedicated team focused on the development of E-Flex based vehicles and that team needed its own creative space,” said Ed Welburn, Vice President, Global Design.

“To accelerate the programme, we needed the right mix of designers and engineers from the original show car team and people with experience from the production side.”

Bob Boniface, design director for the E-flex Systems Design Studio and the Chevrolet Volt, will lead the team of approximately 45 creative designers, sculptors, design engineers, scientists and administrative staff. He was the lead for the exterior design of the Chevrolet Volt concept. According to Boniface, this historical programme offers a new set of challenges and opportunities.

“We handpicked a team of both young and experienced designers who are enthusiastic, eager and believe in the cause as I do,” said Boniface. “They want to find a better way, a solution to our dependency on petroleum, and that’s what this car is about.”

The studio renovation began last June within the existing GM Advanced Design Center. What’s now the new E-flex studio was once an auditorium built for product reviews and other special events hosting famous entertainers and even several former U.S. presidents.

The new studio is an adaptive reuse of the existing facility with steps taken toward environmental sustainability with such installations as sustainable carpet, energy efficient, compact fluorescent lighting; repurposed surfaces, energy efficient window shades to control heating and cooling, rugs made of 100% wool, natural materials, Cradle to Cradle certified furniture that’s recyclable or can be safely composted.

(Source: Chevrolet)