How to make a precision vehicle
By Gary S. Vasilash
“Cars are primarily made from steel, and we need dies to produce the body parts. The precision of the die determines the quality of our cars. At Mazda, we use machine processing to create dies with high precision, but then our Takumi add the final touches by hand to achieve ‘KODO Design.’
“’KODO Design’ uses the play of light and shadow to create designs that make people feel like the car is a living being. To achieve this beauty, our dies must be perfect down to the micrometer level.”–Chiharu Saeki, a technical engineer in the Tool & Die Production Department, Mazda Motor Corporation
A couple things to think about regarding that quote:
- Stamping dies are used, of course, to produce body panels in presses that produce from 1,000 to 5,000 tons of force. The stamping dies that go within the presses are larger than the object being produced. For example, while a door might measure 1.2 meters by 1 meter, the die will measure 2.5 meters by 2 meters. The business portions of the dies (i.e., the areas where the forming occurs rather than the support structure) are made with extremely durable tool steels. And know that not only are they dimensionally big, but they are massive, generally weighing from 50 tons to 72 tons.
- A micrometer is one millionth of a meter. The width of a human hair is about 80 micrometers.
Certainly to make a die some serious machining is required at the start of the process in order to remove steel. Realize it starts with a rectangular blocks of steel that must have forms cut into both the female and male sides of the dies.
But precision machining notwithstanding, the Mazda craftspeople then look at the surfaces generated by the machining and make minor adjustments to those surfaces with hand tools.
One could argue that when dealing with micrometers this might not be noticeable to the end consumer of the product. But (a) “might not” doesn’t mean they don’t and (b) the people at Mazda think it important that they do their very best, so good isn’t good enough.
And while on the subject of things at the microscale, Mazda uses a painting process that its engineers developed that puts a precision reflective paint layer on the surface measuring about 5 micrometers, compared to the typical automotive layer that is 20 or more times thicker. By using the precision process Mazda creates what are some of the best finishes in the automotive world—and it helps that it is applied to surfaces produced by attention to the details of the die surfaces.

Which brings us to the Mazda CX-70, which is built in the Mazda Hofu Plant, meaning a place where there are craftspeople, a.k.a. Takumis.
The CX-70 is a two-row crossover that is as long as the CX-90 three-row crossover (because it is based on the same platform. But because it doesn’t have the third row it provides second-row passengers with surprising legroom (39.4 inches) and capacious cargo volume: 39.6 cubic feet with the second row up and 75.3 cubic feet with it folded.
It is powered by a 3.3-liter inline six that produces 340 hp, with supplementation from a 16.6-hp electric motor that aids such things as performing a transparent stop-start (no, not all people are against these systems that serve to save fuel) and the acceleration after a stop. The electricity is provided by a 48-V mild hybrid system. There is an eight-speed automatic transmission. There is standard AWD.
The same level of care exhibited on the exterior is also evident on the interior, both in terms of the surfaces and interfaces that people touch and see and in the use of buttons for frequently used functions (e.g., HVAC; audio). On the subject of audio: Mazda has been working with Bose for literally decades and the sound quality shows what experience can do. (I would suggest the Mazda Design Department take a look at the graphics used by many other OEMs for their embedded navigation systems and borrow some cues.)
Compared to companies that offer competitive products—like the Honda Passport and the Jeep Grand Cherokee—Mazda’s US sales are significantly smaller.
But the thing is: what it doesn’t have in volume it more than makes up for in precision of execution, all the way to the level of microns.













