10 Notable Automotive Design Flaws and Engineering Missteps in Car History

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10 Notable Automotive Design Flaws and Engineering Missteps in Car History

Classic cars parked with ocean view backdrop
Photo by Tanya Barrow on Unsplash

You know, even some of the most storied and well-respected companies within the auto manufacturing world have slipped on the design and engineering side a number of times throughout their history. Throughout the years, designers have risked being too daring, have pursued fad trends too long, and have experimented with technology that simply wasn’t ready for public testing. While some of these decisions produced cars that sold poorly, others produced some truly interesting parts of automotive history.

Being technologically sophisticated and packed with functionality won’t necessarily endear a car to potential customers. In the battle for car sales, styling, proportions, practicality, durability, price and brand all have a bearing and it can only take one or two to go fundamentally wrong to turn what was potentially a triumphant undertaking into a commercial failure.

A look at some of these notorious auto flops serves to remind us that, when it comes to innovation, wisdom needs to be a strong and present component. Every vehicle on the following list tried something new, it just sometimes missed the mark, and these are ten memorable examples of engineering failures, automobile design flaws, and choices that turned potential into showroom rejects.

Pontiac Aztek
Breaking Bad Pontiac Aztek” by zombieite is licensed under CC BY 2.0

1. Pontiac Aztek

The 2001 Aztek offered an interior that was quite versatile, providing consumers with features such as a removable cooler and an available rear tent package made for camping and other outdoor activities; it was marketed toward younger drivers looking for an alternative to the everyday vehicle suitable for their particular lifestyle.

Design Features That Divided Buyers:

  • Versatile interior designed for active lifestyles
  • Removable cooler added practical outdoor utility
  • Optional tent package supported camping adventures
  • Unusual proportions created a polarising appearance
  • Angular styling attracted widespread public criticism

Unfortunately for Pontiac, most of the handy attributes that the Aztek possessed were overshadowed by it styling and design which many consumers just couldn’t come to terms with. The Aztek had peculiar body lines, awkward proportions, an sharp frontal area, with chunky rear profile. As one of the most widely criticized, if it was design intention to be seen, and different than any ordinary car, it styling was far more remarkable than its practical design that Pontiac had engineered for the car.

A car that showed that simple practicality cannot redeem a design not intended to engage with any customers; sold between 2001 and 2005 the Aztek, due to poor sales for an over-styled, imaginative, or if your preferred, bizarre concept car failed, becoming what we now understand as an iconic example of a bold styling attempt on otherwise good if niche concept. A good historical reference to the need for distinguishing flair balanced with wide appeal.

Ford Edsel
Ford Edsel” by nakhon100 is licensed under CC BY 2.0

2. Ford Edsel

Launched in 1958, after a very considerable financial investment from Ford in an endeavor to drum up interest and anticipation for its latest creation. Ford marketed the car as a vehicle of the future which was set to hold a very important place within Ford’s ever expanding model portfolio of cars and provide a model to which discerning customers could now aspire. The arrival of the Edsel had created a huge amount of fanfare.

Factors Behind The Edsel’s Failure:

  • Heavy marketing created unrealistic consumer expectations
  • Distinctive grille became its defining controversy
  • Styling proved difficult for buyers
  • Mechanical problems affected customer confidence
  • Pricing weakened its market competitiveness

However, in terms of styling was considerably more debatable than Ford had planned. Perhaps the most distinctive trait was the vertical “horse-collar” grille, which would soon dominate the characteristic of a vehicle whose overall styling was largely not viewed to be pleasing or appropriate to a mass market. Indeed, rather than setting the Edsel apart in a positive way, a distinctive look became an obstacle to marketing it.

Besides the design flaws, the Edsel also suffered from mechanical issues, a botched marketing campaign and a price range that was hard to justify. Just after two years of being on the road Ford pulled the Edsel from production. The Edsel proved such a spectacular flop that the name Edsel is often linked with commercial blunders and the model itself has become an infamous symbol of unsuccessful car models.

AMC Pacer (1975-1980)
AMC Pacer – Wikipedia, Photo by wikimedia.org, is licensed under CC BY-SA 4.0

3. AMC Pacer

In 1975, American Motors built a Pacer in the firm’s trying-hard-something-new sort of way. It was to be small and space age-large of body width for its segment-its glass house making for what felt like vast interior volumes. In concept, the car would offer something different for a compact on the road.

Distinctive Features Behind The Pacer’s Reputation:

  • Futuristic styling challenged conventional compact designs
  • Wide body created unusual interior space
  • Large glass areas earned “fishbowl” nickname
  • Rounded exterior divided potential buyers
  • Fuel crisis weakened demand for Pacer

This was an instantly recognizable shape, and soon acquired the “fishbowl” nickname. The car actually had a fairly wide track, which could make it stable, but those rounded exterior lines were simply too odd for most customers. A design which could have been ahead of its time for many seemed instead to be odd, thus this Pacer’s visual presentation has been as polarizing as anything with wheels.

Again, this was bad timing for the Pacer. The engine performance was not outstanding and with increasing emphasis being placed on fuel economy after the ‘fuel crisis’ of the 1970s, sales were poor after initial interest waned. Now largely recalled as an ‘odd shape’ rather than a forward thinking machine, the Pacer’s proportions and heavy-glassed styling were nevertheless instrumental in it becoming one of AMC’s most well-known products.

4. Cadillac Cimarron

Cadillac’s Cimarron was introduced in 1982, amidst Cadillac’s struggle to adapt to market shifts and the increasing rise of smaller, luxury cars. Cadillac opted not for a separate, brand-new platform, but rather based the Cimarron on the Chevrolet Cavalier. The thought was to provide Cadillac’s clientele a slightly smaller luxury vehicle, however, its heavy reliance on a mass-produced vehicle resulted in some pitfalls.

Problems Created By Badge Engineering:

  • Shared platform reduced perceived exclusivity
  • Chevrolet similarities weakened Cadillac’s luxury image
  • Higher pricing created unrealistic expectations
  • Limited refinement disappointed traditional Cadillac buyers
  • Weak performance reduced its premium appeal

It resulted in instant challenges for a luxury marque. When the Cimarron looked and felt so similar to the mainstream version, yet had a list price indicating an exclusive, sophisticated position that the car simply couldn’t attain, drivers could recognize the shared lineage under the Cadillac nameplate and the Cimarron could never carve out an identity on its own for a more exclusive buyer.

And frankly, it wasn’t plush or character-filled enough to meet the public perception of Cadillac either. For those reasons, the Cimarron serves as the classic warning tale for the dangers of “badge engineering,” or, put simply, charging much more money for an essentially identical car while putting a different badge on it. It showed that sometimes you can’t even fake it with luxury through a shiny new badge.

Aston Martin Lagonda” by nakhon100 is licensed under CC BY 2.0

5. Aston Martin Lagonda

4 Aston Martin Lagonda It was a wildly ambitious shot at producing a super futuristic luxury sedan The Aston Martin Lagonda first showed its face in 1976 with a wedge body and of course futuristic for the day digital dash system; nothing like you’d find in a most other cars these days. This is kind of definitive Aston Martin’s go for breaking with usual luxury car formula.

Challenges Created By Futuristic Technology:

  • Wedge-shaped styling divided luxury-car buyers
  • Digital dashboard introduced advanced electronic systems
  • Early components created frequent electrical problems
  • Complex technology increased ownership frustrations
  • High pricing restricted its overall appeal

They were brilliant technologically, but problematic practically. The sophisticated electronic and (early digital) components were sometimes prone to failure and frustrated owners with electrical bother. Their styling was radical and also controversial and the sharp lines and strange proportions alienated many of the conservative luxury car buyers. So what looks good on paper can be difficult to live with day to day.

Expensive tech, electronics unreliability and the sky-high sticker Price all contribute to the Lagonda’s niche status. Nonetheless, its experimental nature does ensure it remains a vehicle of historical interest, highlighting how even advanced tech can be a drawback if the back-up infrastructure cannot support it in everyday operation, particularly on an upscale flagship where such items were even more critically required.

Renault Avantime
Renault Avantime” by crash71100 is licensed under CC CC0 1.0

6. Renault Avantime

The Avantime was launched in 2001 as the French firm tried its hand at creating a car that would defy all car classifications. A blend of MPV, luxury car and sports coupe that combined some of a people-carrier’s pragmatism with the style of a low-riding sports machine, the boxy Avantime had lots of glass, a rakish roof and those huge, pillarless doors. Renault clearly weren’t afraid to have a laugh at the expense of a convention.

Design Choices That Created Market Challenges:

  • Combined minivan and coupe characteristics
  • Large glass areas created distinctive visibility
  • Pillarless doors reinforced its unconventional design
  • Limited practicality weakened its family appeal
  • Unusual styling restricted its customer base

It was an odd notion, and the fact that it was odd, provided practical compromises. The Avantime offered neither the practical family fun that you would expect from a mini-van, nor did its proportions and styling offer the stylish appeal that would define a normal coupe, putting the vehicle in a class of its own where it failed to fulfill any of the previous three.

Which left Renault with something in an unenviable niche on the market the styling might have been too challenging to tempt traditional buyers, but there just wasn’t the level of practicality to truly sell the whole notion. Sales just never took off in any great numbers and it was withdrawn soon after introduction as an interesting case of what seemed to be an idea somewhat prematurely designed.

7. Nissan Murano CrossCabriolet

Nissan, in particular, took an incredibly strange approach with its 2011 Murano Cross Cabriolet. From concept, they basically turned a crossover SUV into a soft-top, two-door convertible-a mash-up virtually unheard of in the production-car space, and one designed to capitalize on a brand-new segment-the crossover with an aspirational open-top appeal and the perceived capability and slightly elevated ride height.

Unusual Combination Created Practical Compromises:

  • Crossover body received a convertible roof
  • Two-door layout reduced everyday accessibility
  • Open-top design created awkward proportions
  • Limited seating reduced its family practicality
  • High pricing restricted its potential audience

On paper it looked like it was a good idea but once in production had very awkward proportions and it simply doesn’t work on an aesthetic level. The bulk of a crossover body didn’t sit well with the removable-roof configuration, and the modifications also chipped away at the practicality SUV buyers are likely used to. Instead of adding the benefits of two types of car, it adds the drawbacks of both to such an extent that its purpose is quite unclear.

Expensive and aimed squarely at an elite niche, the lack of usable rear seats and trunk didn’t make the compromise any easier to stomach, and Nissan killed it off in 2014 after only five years. So it goes down in automotive history as one of the more curious attempts to establish a completely new segment of cars. The short lifespan can teach us a lesson about how hard it is to create a market from scratch around an unlikely pairing.

8. Lincoln Blackwood

Ford Lincoln launched itself into the luxury pickup market in 2002 with the Blackwood, intended to mix top-flight persona with pickup work capability, complete with decadent amenities like a power-operated tonneau cover over a carpeted pickup bed. It was a car in the guise of a truck aiming to capture buyers who craved all the perceived benefits of a luxurious vehicle but didn’t want entirely do without some basic truck function.

Luxury Features That Limited Truck Utility:

  • Carpeted cargo bed restricted practical hauling
  • Power tonneau cover added luxury convenience
  • Rear-wheel drive limited overall versatility
  • High pricing increased its market challenges
  • Limited utility weakened its pickup appeal

All of these attributes pointed to the truck’s fundamental flaw. A carpeted truckbed wasn’t ideal for customers seeking to haul anything dirty or functional, and the truck was only available in a rear-wheel-drive configuration. This left too little utility for the customer expecting a true work truck.

The expensive price just didn’t help this compromise stand out too much. Realistic truck buyers had much better options and luxury buyers did not necessarily see the value in such a peculiar blend. It only made it through one model year before Lincoln scrapped it, and was definitely a learning experience in what not to do with a truck if you are going to add luxury.

Chevrolet SSR
2004 Chevrolet SSR” by NZ Car Freak is licensed under CC BY 2.0

9. Chevrolet SSR

But when the Chevrolet SSR, or Super Sport Roadster, debuted back in 2003, it rolled out with a design concept that practically was unlike anything else in the Chevy stable. Blending a look derived from the classic mid-’50s pickup with a retractable roof, the car basically aimed to be a roadster, but one you could load some groceries into. It was meant to have that kind of unique flair to appeal to consumers looking for something different than a sportscar and something even bolder than your typical truck.

Performance And Market Challenges:

  • Retro styling created strong visual recognition
  • Retractable hardtop added distinctive functionality
  • Heavy body limited overall performance
  • Early V8 struggled with substantial weight
  • High pricing restricted its potential audience

Its distinctive design attracted attention, but the heavy body created challenges for performance. Early versions used a 5.3-litre V8 that could feel underpowered when moving the substantial chassis, particularly considering the sporty image Chevrolet was trying to establish for the vehicle. The combination of considerable weight and modest early performance made it harder for the SSR to deliver the driving experience suggested by its Super Sport identity.

The SSR also faced a high price, limited practicality, and styling that divided potential buyers. Its unusual proportions made it memorable, but being memorable was not enough to generate strong sales. Chevrolet eventually discontinued the model in 2006, leaving the SSR as another example of an ambitious idea that struggled to find a large enough audience. Its distinctive design nevertheless helped the model maintain a unique place in Chevrolet’s history.

Fiat Multipla
Fiat 600 Multipla” by photobeppus is licensed under CC BY-SA 2.0

10. Fiat Multipla

The Fiat Multipla was introduced in 1998 with an approach that was much more practical inside than its exterior appearance suggested. Its unusual front end featured a distinctive second set of headlights beneath the windscreen, while the bulbous body shape immediately separated it from almost every other compact MPV on the market. Although the styling was unconventional, Fiat designed the Multipla around efficient interior packaging and practical everyday usability.

Innovative Packaging Behind Unusual Styling:

  • Compact dimensions maximised available interior space
  • Six seats accommodated passengers across two rows
  • Three-abreast seating improved overall cabin flexibility
  • Distinctive headlights created a controversial appearance
  • Practical design benefits were overshadowed by styling

Despite the criticism aimed at its styling, the Multipla was genuinely clever from a packaging perspective. It could seat six people across two rows of three, making excellent use of its compact dimensions. Its interior demonstrated that unconventional design could produce real benefits when engineers focused on space and flexibility, giving the Multipla a level of practicality that was unusual for its size.

Unfortunately, the exterior became the defining feature of the vehicle in the eyes of many potential buyers. The Multipla’s practicality was often overlooked because its styling was so divisive. It remains a memorable example of how an innovative and functional vehicle can struggle commercially when its visual design becomes a major barrier to consumer acceptance.

John Faulkner is Road Test Editor at Clean Fleet Report. He has more than 30 years’ experience branding, launching and marketing automobiles. He has worked with General Motors (all Divisions), Chrysler (Dodge, Jeep, Eagle), Ford and Lincoln-Mercury, Honda, Mazda, Mitsubishi, Nissan and Toyota on consumer events and sales training programs. His interest in automobiles is broad and deep, beginning as a child riding in the back seat of his parent’s 1950 Studebaker. He is a journalist member of the Motor Press Guild and Western Automotive Journalists.

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