Design of electric cars faces a significant growth all over the world. Powered by rechargeable batteries these vehicles can contribute significantly to the reduction of the big cities' pollution. The shape of a vehicle in our times is of major importance for the market and it represents the car's philosophy and character. Styling requires the definition of the general dimensions and layout of the car in advance. Computer aided techniques were developed to support a systematic design process of E-240, a 2400 mm long electric mini-car, developed at the University of Patras.