Vehicle Sheet Metal Design: Why the bad designs?

If you don't like modern automotive designs, then go make one of your own.

Just remember that once the design has been made, then it has to be able to be mass produced at a cost that will allow the manufacturer to make a profit, and to meet all required safety regulations concerning the design and placement of lights, bumpers, windows, etc.

First off, price IS a factor whether or not you think it should be. If company A is selling a bland looking car for $25K and company B is selling a similar car in every way except for styling but must charge an extra ~$2K per car to cover the elaborate design costs, company B's cars are going to be at a disadvantage in the marketplace. Not everyone wants to spend extra money for styling.

Secondly, bland car designs sell well historically. Especially in the USA. Look at the best-sellers list for the last decade - you'll see a lot more "boring" Camrys, Accords, and F150s on the list than aggresively styled cars and trucks that look like they came right from the stage at an international auto show and into a dealership near you.

Third, in most cases people buy cars where form follows function and not the other way around. Most customers aren't willing to sacrifice cargo space, passenger room, or practicality in the name of styling. That's why you see far more 3-box 4-door family sedans designs on the road than good looking but impractical 2-door sports cars, even when their sale prices are often comparable.