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Calty Design Research

Calty Design Research, Inc. (commonly known as Calty) is a North American studio and wholly owned subsidiary of Motor Corporation, specializing in concept and production vehicle design for and brands. Established in 1973 in , Calty was the first design operation opened by a major automaker outside , initially as a with Yachioda Sangyo (a Toyota affiliate) to foster creative innovation free from traditional manufacturing constraints; Yachioda's involvement ended in 1999, after which it became fully owned by . The studio operates two facilities: its headquarters in , focused on advanced concept and future mobility design, and a production design center in , opened in 2004 to support North American vehicle development. Over its 50-year history, Calty has contributed to numerous iconic vehicles, including the second-generation (1978, which won Motor Trend's Import Car of the Year), the original (1997, the world's first mass-produced hybrid), the Lexus LC 500 (inspired by the 2012 LF-LC concept), the 2020 (from the 2014 FT-1 concept), the 2007 , the 2006 FJ Cruiser, and the 2024 . Calty's designs emphasize bold aesthetics, cultural relevance to North American markets, and forward-thinking mobility solutions, such as the 2021 Lexus Electrified Sport concept and the Baby Lunar Cruiser, helping shape Toyota's global design language while influencing production models like the Tacoma, , and Grand Highlander.

History

Founding and Early Development

Calty Design Research was established in 1973 in El Segundo, California, by Noritsuna Watanabe, general manager, and David J. Stollery, an American designer, as Toyota's inaugural North American design studio. It was initially a joint venture with Ya-chioda Sangyo, a Toyota affiliate and industrial machine trading company that held a 20% stake; the name "Calty" derives from CALifornia, ToyoTA, and Ya-chioda. This facility marked the first U.S.-based design operation by a major Japanese automaker, strategically positioned in Southern California to better comprehend American consumer preferences and adapt Toyota's vehicles for the local market. Initially housed in a warehouse near Los Angeles International Airport, the studio began with a small team of six designers and a total staff of 25, focusing on exploratory styling work to bridge cultural design differences. In 1976, Toyota appointed Kazuo Morohoshi, an assistant manager from its Japanese design division, to lead and restructure the studio amid early operational hurdles in aligning Japanese engineering with Western aesthetics. Under Morohoshi's , Calty shifted its emphasis toward designs tailored to tastes, emphasizing bolder exteriors and more spacious interiors to appeal to U.S. buyers. This pivot enabled the studio's first significant production contribution: interior and exterior styling proposals for the second-generation , launched in 1978 and targeted specifically at the North audience. The studio's early years also benefited from external expertise, including design consultant Strother MacMinn, a prominent Art Center College of Design faculty member who advised on establishing the California outpost and fostering innovative concept development. In 1978, Calty relocated to a larger, purpose-built facility in Newport Beach, enhancing its capacity for comprehensive styling proposals across vehicle interiors and exteriors. Ya-chioda Sangyo's involvement ended in 1999, after which Calty became fully owned by .

Key Milestones and Expansion

In 1978, Calty Design Research contributed to the design of the second-generation (A40 series), which received the Import award, marking an early recognition of the studio's influence on Toyota's North American market vehicles. The studio achieved a significant victory in by winning Toyota's global design competition for the first-generation Prius, establishing Calty's role in pioneering aesthetics. In 1998, Calty celebrated its 25th anniversary with a special event attended by Toyota Chairman and Honorary Chairman , highlighting the studio's growing integration within the family. Expansion continued in 2004 with the opening of Calty's Ann Arbor studio in , aimed at supporting the design needs for Toyota's expanding North American production facilities and enhancing collaboration with engineering teams. By 2007, Calty played a key role in the design of the second-generation pickup truck, incorporating American market preferences into its bold styling. In 2012, the studio led the development of the LF-LC concept, which evolved into the production LC 500 , showcasing Calty's expertise in luxury performance design. The 2020 revival of the (A90) featured significant design input from Calty, blending heritage elements with modern sports car proportions in collaboration with . Calty marked its 50th anniversary in 2023 with a major celebration that included the public reveal of archival unbuilt concepts, such as the MX-2 mid-engine sports car from the , underscoring the studio's enduring legacy in innovative design exploration. Over the decades, Calty has grown to support Toyota's shift toward battery electric vehicles (BEVs) and future mobility solutions, expanding its workforce and capabilities to address sustainable and autonomous design challenges.

Facilities

Newport Beach Studio

The Newport Beach Studio of Calty Design Research, located in Newport Beach, California, serves as the primary advanced design facility dedicated to future-oriented innovation and creativity for Toyota and Lexus vehicles. Established initially in El Segundo in 1973 as Toyota's first North American design operation, it relocated in 1978 to a larger, purpose-built campus in Newport Beach to accommodate growing needs and foster a more expansive creative environment. This move emphasized the studio's role in exploratory concept development, drawing on Southern California's vibrant automotive culture to inspire bold, market-specific proposals. The studio specializes in interior and exterior styling for advanced, non-production concepts, enabling designers to push boundaries beyond immediate manufacturing constraints. Its facilities support hands-on creative processes, including sketching, 3D sculpting with plaster models, and scale modeling to visualize innovative forms and functionalities. These methods allow for rapid iteration on forward-looking ideas, such as aesthetics and sensory-focused interiors, integrating California's laid-back yet progressive cultural influences—like proximity to influential design schools such as the Art Center College of Design—to infuse designs with expressive, organic elements. This complements the Ann Arbor Studio's emphasis on production-ready development by prioritizing conceptual exploration, ensuring a pipeline of visionary proposals that evolve into influential and designs. Over decades, the Newport Beach location has maintained continuity from Calty's founding ethos, adapting to technological shifts while preserving a collaborative space for diverse teams to innovate freely.

Ann Arbor Studio

The Ann Arbor Studio of Calty Design Research opened in 2004 in Ann Arbor, Michigan, as a dedicated facility to advance production design development specifically tailored for North American markets. This establishment aimed to localize vehicle design efforts, enabling Toyota to create vehicles better suited to regional preferences and manufacturing capabilities. Positioned adjacent to the Toyota Technical Center, the studio facilitates seamless collaboration with engineering and technical teams, leveraging its proximity to the U.S. automotive industry's core hub for efficient integration of design and production feasibility. The studio's primary role centers on refining designs into executable forms ready for , with a strong emphasis on practical elements such as production color and wheel concepts. Staff at Ann Arbor coordinate closely with U.S. production facilities to incorporate manufacturing feedback, ensuring designs align with processes and cost efficiencies. This production-oriented approach contrasts with the exploratory concept work at the Newport Beach Studio, focusing instead on transitioning initial ideas into manufacturable realities. A key example is the studio's contributions to the 2007 second-generation , the first production vehicle fully designed there, which integrated direct input from manufacturing teams to optimize its full-size pickup configuration for North American .

Design Philosophy

Core Principles

Calty Design Research embodies a design philosophy rooted in the "California cool" aesthetic, which emphasizes a laid-back yet innovative vibe inspired by the region's diverse culture and environment. This approach draws from , , and everyday experiences to create that evoke emotional connections, such as through forms reminiscent of vacuum-sealed or sculptural techniques like plaster balloons, infusing and models with a sense of approachable sophistication. The studio adapts Toyota's renowned Japanese engineering precision to align with U.S. consumer preferences for bold, expressive styling that prioritizes and market-specific needs, such as compliance with pedestrian safety regulations while maintaining aesthetic appeal. Under the leadership of Kazuo Morohoshi starting in 1976, Calty shifted from replicating Japanese designs to fostering market-specific , relocating to a larger Newport Beach facility to enhance creative output and collaboration with Toyota's global vision. Calty demonstrates a strong commitment to sustainability through forward-thinking mobility solutions, particularly in battery electric vehicle (BEV) concepts like the Lexus Electrified Sport, which integrate electrified powertrains to address environmental challenges. The studio also plays a key role in developing advanced color, wheel, and material concepts tailored to North American tastes, selecting scents, lighting, and textures to enhance interior emotional resonance and functionality.

Design Process

Calty Design Research employs an that begins with ideation and initial sketching at its Newport Beach studio, where designers focus on creative exploration and future-oriented concepts using traditional pen-and-paper techniques alongside early digital modeling to establish visual directions. This phase emphasizes freedom in drawing inspiration from diverse sources, allowing teams to generate rough concepts that capture innovative forms before advancing to more structured digital representations. As designs progress, they move to the Ann Arbor studio for refinement and production development, incorporating and 3D CAD to build and iterate on physical and virtual prototypes. This handover facilitates a seamless transition from conceptual creativity to practical execution, with continuous feedback loops ensuring alignment with engineering constraints through feasibility studies and problem-solving collaborations. Throughout the process, Calty collaborates closely with Toyota's headquarters in and U.S. engineering teams, participating in global competitions to propose solutions tailored for international markets. A notable example is the 1997 Prius competition, where Calty's submission won by presenting photographs of the clay model in real-world environments, demonstrating innovative presentation that influenced the final production . Advanced tools such as studios enable real-time sharing and validation with global partners, while color and material testing refines aesthetic and functional elements during iterations. Feedback mechanisms integrate consumer and cultural insights to adapt designs for North American preferences, drawing on to respond to evolving views on vehicle functionality and appeal. This includes evaluating emotional and sensory responses to ensure regional relevance, with iterative refinements addressing feedback from multidisciplinary teams. The culminates in the transition to , where concepts are finalized with detailed work on wheels, , and overall feasibility, often condensing bold ideas into manufacturable forms through close coordination with and groups. Tools like modeling mills accelerate physical prototyping, allowing rapid adjustments to detailing before executive reviews and handover to .

Notable Contributions

Production Vehicles

Calty Design Research's contributions to production vehicles have significantly shaped and models for the North American market, emphasizing American consumer preferences, functionality, and innovative aesthetics that transitioned from studio sketches to manufactured reality. The second-generation , launched in 1978, marked Calty's debut in production vehicle design, with the studio leading exterior styling tailored to American tastes through angular lines and sporty proportions that enhanced its appeal as a compact . This design incorporated Americanized features such as improved for U.S. drivers, contributing to its commercial success and earning the Import Car of the Year award in 1978. In 1997, Calty secured a global design competition to define the aesthetics of the first-generation , the world's first mass-produced , focusing on aerodynamic efficiency and a futuristic yet approachable form that symbolized environmental . The resulting design, refined using real-world photography for validation, helped the Prius win Japan's award upon its debut. The 2007 second-generation Toyota Tundra represented a milestone as the first full production design from Calty's Ann Arbor studio, encompassing both exterior and interior elements with bold, muscular lines and spacious cabins optimized for North American full-size truck buyers. This comprehensive approach emphasized durability and capability, setting a new standard for Toyota's truck lineup in the U.S. The 2006 originated from a concept developed at Calty, featuring retro-inspired styling drawn from the original FJ40 with a narrow grille, round headlights, and rugged off-road proportions that captured adventure aesthetics for modern consumers. This design evolved directly into production, blending nostalgic elements with contemporary functionality to appeal to North American enthusiasts. For the 2000 Toyota Avalon, Calty provided North American-specific styling refinements, enhancing the sedan's elegant proportions and comfort-oriented details to better suit U.S. family sedan preferences while maintaining Toyota's reliability ethos. Calty's design for the original 1995 Toyota Tacoma emphasized durable, adventure-oriented aesthetics with rugged lines and practical proportions that appealed to off-road enthusiasts, establishing the midsize pickup's iconic tough-yet-approachable identity. The studio revisited this heritage for the 2024 Tacoma update, leading the exterior design under the theme of a "Badass Adventure Machine," drawing inspiration from Baja race trucks to incorporate a high-lift stance, slim body, and athletic power for enhanced off-road capability and visual aggression. The 2024 Land Cruiser's exterior was primarily designed by Calty, adhering to a "" philosophy that revived the vehicle's rugged heritage through simple, powerful shapes and a heroic presence, blending timeless authenticity with modern off-road prowess as part of a global team effort. Calty drove the revival of the 2020 Supra, evolving its performance-focused lines from the 2014 FT-1 concept with a long nose, compact cabin, and dynamic "double bubble" roof that echoed the model's legacy while introducing a "Condensed " aesthetic for agile handling and emotional appeal. The 2012 Lexus LF-LC concept, crafted at Calty, directly influenced the production LC 500 grand touring coupe, featuring spindle grille accents, muscular rear haunches, and L-finesse proportions that defined a new era of design language, earning the 2015 EyesOn Design Award for production vehicle excellence.

Concept Designs

Calty Design Research has been instrumental in developing visionary concept vehicles that explore innovative forms, materials, and technologies beyond current production constraints. These projects often serve as platforms for experimentation, influencing and 's future directions in styling and functionality while remaining largely unproduced. One prominent example is the FT-1 Concept, a rear-wheel-drive unveiled at the 2014 in . Designed entirely at Calty's studios, the FT-1 drew inspiration from Toyota's heritage models like the 2000GT and Celica, featuring aggressive proportions, a long hood, and a low-slung profile to evoke pure performance. Initially conceptualized for the , it transitioned to a full-scale show , highlighting Calty's ability to blend digital and physical design processes. In the segment, Calty contributed the Coupe Concept, a sleek four-door that reimagines elegance with flowing lines and a bold grille. Revealed at the 2025 , the concept emphasizes premium proportions and advanced surfacing to explore new forms, developed under Calty's to push aesthetic boundaries. Advancing electrification, the Electrified Sport BEV concept, introduced in 2021 by then-Toyota Chairman , represents Calty's vision for high-performance battery-electric vehicles. This two-seat successor to the LFA incorporates aerodynamic efficiency and dynamic styling, with sketches led by Calty's senior designers to envision sustainable performance. Unveiled as part of a broader BEV lineup, it explores in-wheel motor integration and futuristic cabin interfaces. For extraterrestrial applications, Calty created the Baby Lunar Cruiser (BLC), a compact, all-electric debuted in 2023 to mark the studio's 50th anniversary. Drawing from the FJ40 Land Cruiser's rugged heritage, the BLC features airless tires, in-wheel motors, and controls for lunar exploration, blending adaptive technology with adventurous styling. In 2023, Calty opened its archives to reveal several unbuilt projects, showcasing decades of internal innovation. Among them was the MX-2, a mid-engine from the with gullwing doors and a liftable rear canopy, evoking supercar drama through curved . Earlier concepts included 1970s and 1980s sports car studies like the MX-1, an alternate FJ40 proposal, and high-performance prototypes that tested radical forms never intended for production. These archives highlight Calty's exploratory , with designs that influenced subsequent vehicle evolutions. Through these efforts, Calty consistently pushes boundaries in , and advanced styling, developing experimental palettes, custom architectures, and forward-looking that inform but precede realities. For instance, concepts like the BLC incorporate novel color and finishes for extreme environments, while studies explore unconventional designs for enhanced dynamics. This role in color, , and finish (CMF) innovation allows Calty to prototype trends in and surface treatments not yet viable for mass-market vehicles.

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