Volvo is renowned for its design-focused offerings and vehicles with sleek aesthetics. However, most of the Swedish car manufacturer’s products initially adhere to a set of guidelines around which they must design. While artistic design remains crucial, it is not the overriding factor. Various elements such as government regulations, platform-sharing limitations, productionchallenges, and customer expectations can influence the appearance of a car. With the introduction of the new 2022 Volvo C40 Recharge, Volvo’s designers took all these considerations into account and created a practical, compact SUV that addressed the design obstacles posed by a sloping roofline to emerge as something distinct.
Commencing as a sketch—an offshoot of the existing XC40 Recharge design, challenges arose in transforming a concept into a fully functional vehicle. Nevertheless, Volvo’s designers viewed these challenges as opportunities to create an even more remarkable C40. To gain insights into these challenges, I engaged in a discussion with Volvo’s design trio: T. Jon Mayer, the head of exterior design, Lisa Reeves, director of interior design, and Robin Page, the overall design director. Through our conversation, I pinpointed several aspects of the C40 where I noticed the most intriguing decisions taking shape. (Although I currently write about automobiles, my educational background lies in industrial design). It turns out that every decision contributing to the current form of the C40 Recharge has a unique story behind it.
Volvo
The initial challenge involved resolving the issues linked to a slanted, fastback roofline—a common feature found in many contemporary SUVs. While the benefits of such a design may appear primarily aesthetic, that isn’t the complete picture. A fastback design offers reduced aerodynamic resistance compared to a traditional, non-sloping roofline such as the one on the Volvo XC40 Recharge. In the realm of electric vehicles, it’s imperative to minimize aerodynamic drag as much as possible, as a less aerodynamic vehicle can translate to considerably reduced range.
Nevertheless, individuals with larger builds know that a sloped roofline can impede back seat headroom. To address this issue, Volvo’s designers adopted a strategy akin to the one used in the Mustang Mach-E by incorporating a blacked-out extension of the car’s roof to provide increased headroom for rear passengers. This design feature is divided into two distinctive bulges, generating a more dynamic appearance, enhancing headroom, and preserving the aerodynamic benefits of the roofline. This exemplifies intelligent design.
Nevertheless, the roofline isn’t the sole factor contributing to extended range. The C40 boasts meticulously engineered aerodynamic wheels—a component of a car’s design often overlooked by consumers but deliberated upon painstakingly by Volvo’s designers. “We might struggle with it—and strive to refine it endlessly—to the hundredth of a millimeter,” Mayer shared. Yet, ultimately, the customer may not be aware of or concerned about this struggle. “From the customer’s viewpoint, they might appear identical,” Mayer elaborated. Reeves suggested that the ideal response would be something along the lines of, “Impressive wheels!”
The vehicle’s tail lights showcase another aspect of deliberate design, although not without its share of obstacles. Mayer disclosed that the tail lights presented an opportunity to introduce a distinctive visual element. Initially envisioning a large rear tail light resembling that of a Volvo, the designers intended for it to gracefully wrap around the sloping roofline with a continuous stroke of light. Despite the need for a break in illumination for the tailgate, minimizing additional breaks was the goal. Regrettably, the engineers deemed the original concept unfeasible.
This ongoing clash between designers and engineers is commonplace across industries. Page referred to it as a love-hate relationship. “We challenge them, and they detest being challenged. Yet, ultimately, problem-solving together fosters a productive environment,” he expressed.
In this scenario, the engineers prevailed as the upper taillight lens would consist of two separate plastic pieces. The desired continuous stroke of light was unattainable, resulting in necessary breaks. Responding to this limitation, the designers incorporated additional breaks, forming a distinctive segmented lighting signature. They seized an opportunity within the engineering constraints.
Volvo
In my few stints in design roles, I’ve encountered such instances in virtually every crafted item that few may truly grasp. To echo Page’s sentiments, “Every designer likely harbors tales about every minute adjustment made.”
One notable area is Volvo’s extensive efforts to seamlessly incorporate the myriad cameras and sensors of modern cars into their exteriors. When questioned about less appreciated aspects that his team values greatly, Mayer pinpointed the importance of concealing or ensuring flush integration of all driver-assist sensors on Volvo vehicles. While these subtleties may elude the average consumer’s notice, any deviation from this standard would likely become a point of contention.
“Our aim is seamless integration,” Mayer elaborated. “Achieving flush alignment elicits considerable excitement among our exterior designers. Yet, for the average consumer, it may hardly register.” He proceeded to mention how these electronics are now factored in from the outset, and certain intrusive sensors may subtly influence the vehicle’s design, like the front-facing camera placement.
Volvo
However, not all of Volvo’s design subtleties. A prominent aspect of the new C40 that garners appreciation is its interior, as detailed by the company’s head of interior design, Lisa Reeves. Featuring “leather” seats crafted sans animal products—referred to as “micro-tech soft material largely sourced from recycled materials”—the C40 offers a premium cloth interior derived from wool, emphasizing sustainability. A substantial portion of the interior upholstery and carpets entails recycled plastic water bottles. These materials prioritize lightweight comfort, minimizing the use of raw petrochemicals.
“Our future-conscious clientele increasingly seeks eco-friendly alternatives,” Reeves noted. She highlighted how collaborating with these sustainable materials allows for expanded creative latitude. Finally, there’s more than just different opportunities for modern designers to innovate.
There are numerous kinds of leather available, which is “truly thrilling” for Reeves and the interior crew at Volvo.
Another exciting feature in the car’s interior is the continuation of the vehicle’s distinct lighting signature. Instead of a piece of wood on the dashboard—although wood is debatably a highly sustainable material—a backlit topographic map of one of Sweden’s national parks, Abisko, is presented to connect the interior back to nature. This stylized feature isn’t flat either. It possesses a subtle curve that adds a fascinating dimension to it, making it even more remarkable.
The design stretches from the dashboard to the doors, enveloping the driver and passengers with a touch of nature wherever they travel, if they embrace the symbolism.
Volvo
In terms of interior lighting, disregard the vibrant RGB lighting encircling the interiors of vehicles like the new S-Class or a logo projected by the door on the ground. This approach is more subtle, more purposeful. It would be inaccurate to use the term “restrained” here. It seems that almost every part of the new C40 has a story behind it. An encounter, a moment, a locale—it’s a vehicle not solely dictated by a sequence of engineering limitations but a unique representation of a car brought to life by a group of individuals with a genuine vision.
Just to emphasize, this is not merely a concept vehicle that you’ll see in pictures but never have the opportunity to drive. The C40 Recharge is tangible and offers a range of 210 miles, albeit it treads a fine line due to not using an EV-exclusive platform and potentially having lower mileage than some buyers may find satisfactory. It also offers a slightly smaller interior compared to its electric XC40 counterpart (but gains two additional miles of range).
These are two valid concerns, yet neither can diminish the essence of this vehicle. It’s a considerate design in a time when the modern “charge it like your phone” car is increasingly prevalent. Electric vehicles don’t need to be mere appliances, nor do they need to be overly aggressive to convey their essence. All they need to be is a bit more meticulously thought through, like the C40 Recharge.
Volvo
Have a tip or query for the author? Feel free to contact them here: peter@thedrive.com
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