The Art of Designing within Constraints: A Conversation with Hossein Vafaei on Cozy Corner
In the latest episode of Cozy Corner with Hossein Nasiri, the spotlight was on Hossein Vafaei, an automotive designer and the Head of Design at Kerman Motor Company (KMC). Vafaei shared his inspiring journey of turning childhood dreams into reality, his experiences working with global automotive giants, and his current endeavors in shaping Iran’s automotive landscape. The discussion delved deep into the intersection of creativity, engineering, and industry constraints, offering an illuminating perspective on the often-overlooked art of car design.
From Dreams to Design
Hossein Vafaei’s passion for automotive design began early. Pursuing his dream, he studied Transportation Design at IAAD University in Turin, Italy. His career took him to the design studios of prestigious brands like Ducati, Nissan, Mercedes-Benz, and Porsche. Among his significant contributions was working on the new generation of the Porsche 911—a testament to his talent and dedication.
Despite the allure of Italy and the global automotive industry, Vafaei chose to return to Iran. This decision was driven by his desire to cultivate a professional culture of automotive design in his homeland and to contribute to the development of the Iranian automotive industry. Over the past five years, he has led KMC’s design team, introducing innovative projects such as the KMC Eagle, the first Iranian-designed car by Kerman Motor, and modernizing the brand’s graphic identity and showroom standards.
The Creative Process: From Sketch to Reality
Car design, as Vafaei explained, is a delicate balancing act—a creative journey constrained by engineering, market expectations, and regulatory requirements. For him, the process begins with a blank sheet of paper, a Bic pen, and a free mind. “It’s like entering another world,” he said, describing the moment when ideas start to flow. The initial phase allows for unfettered creativity, enabling designers to explore bold and innovative concepts without being burdened by constraints.
However, as the design evolves, reality steps in. The sketches must transition into precise 3D models, and eventually, physical prototypes. This stage involves extensive collaboration with engineering teams, navigating challenges such as material limitations, manufacturing feasibility, and cost-effectiveness. Every decision, from the curvature of a windshield to the choice of stitching in the interior, must align with technical, financial, and aesthetic goals.
Designing within Constraints
Working in Iran’s automotive industry presents unique challenges. Sanctions, limited access to advanced technologies, and resource constraints make the job far more complex. Yet, Vafaei views these limitations as opportunities for creativity and innovation. “You’re constantly placed in a constrained framework where you have to operate,” he noted. “It’s like playing football on a defined field, but finding creative ways to score within those boundaries.”
He emphasized the importance of understanding the entire ecosystem—from R&D to supply chains. For instance, in developing the KMC Eagle, his team worked within the confines of an existing platform while introducing fresh elements to rejuvenate the car’s look. The result was a “minor facelift” that showcased innovation despite significant restrictions.
The Role of Concept Cars
Concept cars, according to Vafaei, offer a glimpse into the future. Unlike production vehicles, they are not bound by engineering constraints or market demands. “Concept cars are the true embodiment of free-thinking,” he explained. These vehicles act as a brand’s vision for the future, showcasing potential innovations in design and technology. While many concept features never make it to production, they often serve as inspiration for future developments, subtly shaping public taste and expectations.
The Global Influence on Local Design
Drawing from his international experience, Vafaei highlighted the stark differences between global and local automotive industries. In global markets, collaboration and platform sharing among brands accelerate innovation and reduce costs. For instance, the Stellantis group—a conglomerate of 11 brands including Peugeot, Citroën, and Jeep—demonstrates the efficiency of shared platforms. In contrast, Iran’s closed market has stifled such collaborative opportunities, limiting technological advancements and design freedom.
Yet, Vafaei remains optimistic. He pointed out the adoption of new platforms by Iranian automakers as a step forward. Platforms like those used in the SAIPA Shahin and Iran Khodro Tara reflect a gradual shift towards modernization, providing designers with more flexibility to innovate.
Navigating the Art of Collaboration
A pivotal theme in Vafaei’s work is collaboration. The design process often requires seamless interaction between various departments, including engineering, marketing, and manufacturing. “Design doesn’t exist in isolation,” he emphasized. “Each department plays a critical role in ensuring that the final product meets all expectations, from aesthetics to functionality.”
For example, the integration of advanced lighting systems demands close cooperation with specialized lighting engineers. Similarly, material choices—whether for the dashboard or the car’s exterior—require input from suppliers and production teams. This collaborative approach ensures that every detail aligns with the broader vision.
Education and Skill Development
Vafaei also discussed the importance of education in shaping future designers. He highlighted the curriculum at IAAD University, which balanced artistic training with technical knowledge. “Without understanding the engineering constraints, design remains merely an artistic exercise,” he said. This foundational knowledge equips designers to navigate the complexities of real-world projects.
In Iran, he advocates for similar educational programs to cultivate local talent. By fostering a new generation of designers with a global perspective, Vafaei hopes to elevate the standards of automotive design in the country.
The Psychological Aspect of Design
Beyond technical expertise, Vafaei shed light on the psychological dimensions of design. Designers must anticipate market trends and consumer preferences, often working years ahead of production. “You need the courage to introduce forms and concepts that may seem unusual today but will resonate in the future,” he explained.
This forward-thinking approach requires a deep understanding of cultural and social dynamics. Vafaei drew parallels to brands like BMW and Mercedes-Benz, which have successfully shaped public taste through bold and innovative designs.
Environmental Sustainability in Design
A growing consideration in automotive design is sustainability. Vafaei stressed the importance of integrating eco-friendly practices into every stage of the process. From using recyclable materials to optimizing fuel efficiency, designers play a crucial role in reducing the environmental impact of vehicles.
At KMC, sustainability is a key focus. Vafaei’s team explores innovative solutions, such as incorporating lightweight materials to improve fuel economy and reduce emissions. These efforts align with global trends, where automakers are increasingly prioritizing environmental responsibility.
The Future of Automotive Design in Iran
Vafaei’s vision extends beyond individual projects. He aspires to establish a culture of automotive design in Iran that balances artistry with practicality. He believes in fostering collaboration across disciplines—from design and engineering to marketing and production—to create vehicles that resonate with both local and global audiences.
He also underscored the need for courage in design. Referring to brands like BMW and Mercedes-Benz, he noted how bold design decisions initially faced criticism but eventually reshaped consumer perceptions. “As designers, we must anticipate trends and shape tastes,” he said. “It’s about having the confidence to innovate, even if the initial reaction is negative.”
A Dynamic Process
The automotive design process is as dynamic as it is intricate. From initial sketches to physical prototypes, every stage involves a constant interplay between creativity and practicality. This includes collaborations with specialized teams, such as lighting engineers and material experts, to ensure the final product meets aesthetic and functional standards.
Vafaei’s description of the physical modeling stage was particularly fascinating. Using CNC machines and materials like Epowood, designers create full-scale mockups to analyze proportions and reflections under studio lighting. This meticulous process often reveals nuances that are missed in digital models, emphasizing the importance of hands-on craftsmanship.
Conclusion
Hossein Vafaei’s narrative is a testament to the resilience and ingenuity required in automotive design. His journey—from global studios to leading design at KMC—reflects a commitment to innovation within constraints. Despite the challenges of working in a restrictive environment, he continues to push boundaries, blending artistry with engineering to elevate Iran’s automotive industry.
Through his work, Vafaei not only designs cars but also shapes a vision for the future of automotive design in Iran. His story is an inspiration for creatives everywhere, demonstrating that even within the most confined frameworks, there is room for imagination and growth.
