Process for making complex shapes in cars?

[B.karthik]

Hi friends i saw Audi r8 in a poster and was amazed by its design.I looked into sidepanels in that road car next to the side-doors.It is very complex in shape.How do they design and built that panels?Whats the process?

[Airjer_]

They use a process called hydroforming. It uses water pressure to force the aluminum panels into a mold. They use the same process to build the frames for the corvette as well as many other applications. The panel right behind the door is carbon fiber, which can be made into just about any shape you want.

[KiwiBacon]

Read about some of it here:
https://www.audi-mediaservices.com/p...tlichkeit.html

In addition to hydroforming, you'd be amazing what shapes can be acheived with variations on the traditional sheet metal press and tooling.