ATSUGI, Japan -- One might think the hardest part about executing the curvaceously creased Infiniti Q60 sports coupe would be delicately stamping the scalloped sheet metal.
And its true that Infiniti's manufacturing gurus took pains to align the new car's sharply furrowed shoulder and bulging fenders perfectly across the door and quarter panels.
But Infiniti global design chief Alfonso Albaisa says the real challenge lurks under the skin.
With door gap tolerances of just 2.5 millimeters, getting doors to open and close around Infiniti's deep creases without pinching means some clever kaizen on the hinges.
"When we introduce this depth, this moodiness, this flow, this artistry, that depth makes hinging difficult," Albaisa said in a recent interview at Infiniti's global design studio here, south of Tokyo. "But our engineers actually love this. It allows them to show their expertise. They spend a lot of time with the angle of the hinges, the depth of the hinges."
The fix: complex hinges that allow a door to open and then drop in under the fender.
That is just one of the hoops Infiniti engineers and designers have been jumping through as the Japanese rolls out a new look meant to set it apart from rivals, build on this year's record global sales pace and help lift it out of the lower-tier luxury pack.