Audi 2012 Annual Report Download - page 43

My Perfection
fenders, for example, are a challenge.
The concave and convex surfaces
that meet there must be shaped in
such a way that it looks homogeneous
yet at the same time dynamic.”
“Sometimes you get stuck. You
model dierent variants, but none
of them really fit,” says Müller when
describing the eort of his daily work.
“In these cases, I like to come in on
a Saturday because I am alone here
and can tinker in peace. I usually also
find a solution, and these are special
moments for me.”
These are surpassed only by the
feeling that occurs when a model
receives an enthusiastic response at
a presentation following weeks of
hard work. “By then at the latest you
know that the sweat and overtime
were worth it,” says Müller, who has
often experienced this. Until then,
however, the clay modelers work
behind the scenes, and generally on
multiple pieces at the same time. Four,
five or more clay models are created
and refined step-by-step on the way
to a new Audi. In the end, the final
model is shaped inside and out so that
visually it is almost indistinguishable
from a real vehicle. Windows, radiator
grille, instruments, even remote-
controlled headlights perfect the
illusion. The modelers report that at
one presentation this has resulted in
someone trying to open a door and
ending up with the handle in their
hand. In a way this is also a testament
to the perfection down to the finest
detail – a characteristic feature of all
Audi models.
There is an average of two years
between the initial idea and the
decision whether a clay model will
become a production vehicle. “That
sounds like a long time,” says Sommer
in deep concentration as he draws a
spatula through the modeling clay at
the center console. “But what applies
to fine wine also applies to our work:
It needs time to mature.” «
Finishing touches to the front end:
Volker Ried (left) and Joachim Müller
refine every detail to the very end.
It doesn’t harden like normal clay,
but rather can be heated again and
again using an industrial dryer and
remodeled. “This enables us to make
corrections quickly and easily at any
time,” says Müller. The creation of
the model is a process of constant
changes in which the modelers and
designers work in close collaboration
from beginning to end. “We are in
constant dialogue,” adds Müller.
“Tomorrow we may find a solution
that is better than one we like today.”
The exterior model is covered with
between 500 kilograms and one metric
ton of industrial clay. Four modelers
spend two to three days working on it
before the model takes on its initial,
rough shape – despite the fact that
they only model one side of the vehicle.
This is then covered in measuring
points and scanned millimeter by
millimeter via the photogrammetry
process. The data are used to program
a milling machine that creates a
complete mirror image of the shape
on the unprocessed side of the model
overnight.
Sommer says that modeling is the
best part of his job, “partly because
it comes with a certain amount of
creative freedom. We can contribute
our own ideas, even if it is just a matter
of tiny details. But you take especially
great pride in these. You can then stand
in front of the finished vehicle and
say there is a little bit of me in there.”
Exterior specialist Ried is also familiar
with this triumph. “It is a special
moment, particularly when an area was
complicated and you spent a lot of
time experimenting with it. The front
Visit to the Audi Model
Studio: Experience the clay
modelers at work.
P H O T O S | M A N F R E D J A R I S C H ; J I M R A K E T E
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