In the automotive industry, concealing prototypes is an art designed to elicit that emotional response from consumers when the vehicle is eventually launched. Opel has managed to keep the design of its new Astra a secret despite considerable efforts by prototype paparazzi to unmask the manufacturer’s new hero.

Using cunning camouflage to disguise the new Astra as it began track and open road testing, Opel has kept the prototype paparazzi guessing. The team responsible for disguising the Astra prototype began their work while the Astra was still a computer simulation. Working together with the car’s designers and engineers, the team decided which of the car’s characteristics should be kept hidden from the prototype paparazzi.

Ensuring that these characteristics were indeed kept under wraps entailed developing a “facelift” made using a wooden cast of the Astra. The camouflage itself was then prepared from special adhesive and foil which maintains the car’s smooth surface and is tear proof in extreme temperatures.

In certain areas the foil was shimmed with foam to change the contours of the car. Smaller body panels such as the side mirrors and bodykit were obscured with contrasting covers. Opel used a black and white chessboard pattern for years but recently replaced that with ”fishies”, rounded fish-shaped diamonds designed to confuse camera lenses and spying eyes. The Astra utilises an even more complex camouflage in the form of ‘Flimmies” which has a flickering effect when photographed.

The next trick in the disguise plan was to use false brand or identification marks, thus a camouflaged prototype with an Opel logo on is most probably not an Opel at all. But some body parts such as the front and rear lights which are often used by designers to make the car’s brand more recognisable are difficult to camouflage particularly due to certain restrictions placed by vehicle licensing authorities to ensure public safety. The Astra’s headlights were cleverly altered and disguised without disobeying the licensing authorities’ restrictions.

Another challenge was that the camouflage needed to be removable for acoustics and aerodynamic tests. Whereas some manufactures opt for wrap around covers that are attached to the car with Velcro and lashing belts, Opel responsibly selected a different approach because the wraparound covers may peel off at high speeds damaging the camouflage and posing a danger to other road users.

Opel has clearly taken great care in keeping the true identity of its new Astra hidden until it is launched.