The new C 63 AMG was first constructed as a digital model, the engine, cooling system, fuel system, drive train and axles being "married" with the bodyshell to examine buildability. In spring 2005 the first 1:4-scale design models were produced on the basis of drawings and computer images and, in addition, the first testing and development vehicles were already built on the basis of the preceding C 55 AMG. This made it possible to test major assemblies such as the drive train, brakes and axles. The latest onboard measuring technology provided valuable data such as engine oil, coolant and brake disc temperatures – but other aspects of interest were lap times e.g. on the north loop of the Nürburgring, as well as measurable, precisely defined handling manoeuvres to provide comparisons between different axle configurations. These tests were accompanied by extensive aerodynamic tests on the bodyshell of the C 63 AMG and it was only then that the final design was approved.

Following approval of the concept in the autumn of 2005, the first fully fledged prototypes of the C 63 AMG were built. At the same time the high-performance saloon was also produced as a digital prototype. Computer simulations made it possible for the "real" development prototypes to exhibit a very high level of maturity during the first rollout. These simulations included the most important vehicle functions, such as handling dynamics, the engine and drive train, bodyshell durability, suspension performance, passive safety, the engine's thermal characteristics and performance/fuel consumption.

The standardised and highly sophisticated AMG development and test programme for the C 63 AMG began in summer 2005. Over the next couple of years around 20 vehicles were dispatched all over the world from Mercedes-AMG GmbH in Affalterbach. The objective: strenuous tests in every climatic zone on earth Test, analyse and optimise – that is the creed of the specialists at AMG to achieve the objectives laid down in the book of specifications. Another decisive aspect was an ongoing dialogue between Design and Development, so that any necessary technical modifications were also implemented in design terms.

The major test stages at a glance:

In addition, various endurance trials are run with the aim of simulating the vehicle's entire lifecycle under the most severe conditions:

These tests are supplemented by extensive crash simulations and real crash tests to provide the necessary evidence for country-specific certifications without which no registration would be possible. The end result is final vehicle approval – the green light for the launch of the C 63 AMG.