on a tour of the production facility in Sant’Agata Bolognese.facility in Sant’Agata Bolognese.
When the steel door opens, what emerges When the steel door opens, what emerges are the familiar factory sounds – but they are the familiar factory sounds – but they are more muted than usual
are more muted than usual in this 7,000 square-meter productionin this 7,000 square-meter production facility, which began operations with the Aventador in 2011. “The facility, which began operations with the Aventador in 2011. “The hall, the production processes for the
hall, the production processes for the monocoque and the car weremonocoque and the car were developed in parallel,” explains Massimiliano Corticelli, who con- developed in parallel,” explains Massimiliano Corticelli, who con- ceived the CFRP production system. CFRP stands
ceived the CFRP production system. CFRP stands for Carbon-Fiberfor Carbon-Fiber Reinforced Polymers and they are one of the lightweight design Reinforced Polymers and they are one of the lightweight design secrets of the 700 hp super
secrets of the 700 hp super sports car, which now even comes withsports car, which now even comes with 750 hp in the new Superveloce version.
750 hp in the new Superveloce version. CFRP is the hi-
CFRP is the hi- tech heart of the intelligent lightweighttech heart of the intelligent lightweight design that is the key to maximum performance at Lamborghini design that is the key to maximum performance at Lamborghini .. The creation of the Aventador monocoque is a fusion of hi-tech The creation of the Aventador monocoque is a fusion of hi-tech and craftsmanship. Bathed in daylight, this production hall rou- and craftsmanship. Bathed in daylight, this production hall rou- tinely combines automated processes and highly specialized tinely combines automated processes and highly specialized manual skills. manual skills.
CARROZZERIA
CARROZZERIA
CARBONARA
CARBONARA
Photos Photos Bernhard Huber Bernhard Huber Text Text Michael Harnischfeger Michael Harnischfeger11
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133Well wrapped – Well wrapped –prior to beingprior to being baked in the oven, the beauty of baked in the oven, the beauty of the part is far from apparent. the part is far from apparent. It is wrapped in airtight foil like It is wrapped in airtight foil like a treasure.
a treasure.
Position check –
Position check –four layers of thefour layers of the temperature-sen temperature-sensitive sitive prepregprepreg material make up the roof of the material make up the roof of the Aventador. They have to be very Aventador. They have to be very precisely positioned precisely positioned..
Molded to perfection – Molded to perfection – experienced experienced assembly technicians lay the mats assembly technicians lay the mats into the mold with millimeter preci- into the mold with millimeter preci- sion and position them there. sion and position them there. 1 1 2 2 3 3
Hi-tech Monocoque
Hi-tech Monocoque
The bull brand has been applying enormous expertise in its use
The bull brand has been applying enormous expertise in its use
of carbon-fiber reinforced plastics for the last 30 years. The Aventador
of carbon-fiber reinforced plastics for the last 30 years. The Aventador
is the first Lamborghini with a full CFRP monocoque that is the
is the first Lamborghini with a full CFRP monocoque that is the
perfect symbiosis of li
perfect symbiosis of li ghtweight design and stiffness. We take you hereghtweight design and stiffness. We take you here
on a tour of the production
on a tour of the production facility in Sant’Agata Bolognese.facility in Sant’Agata Bolognese.
When the steel door opens, what emerges When the steel door opens, what emerges are the familiar factory sounds – but they are the familiar factory sounds – but they are more muted than usual
are more muted than usual in this 7,000 square-meter productionin this 7,000 square-meter production facility, which began operations with the Aventador in 2011. “The facility, which began operations with the Aventador in 2011. “The hall, the production processes for the
hall, the production processes for the monocoque and the car weremonocoque and the car were developed in parallel,” explains Massimiliano Corticelli, who con- developed in parallel,” explains Massimiliano Corticelli, who con- ceived the CFRP production system. CFRP stands
ceived the CFRP production system. CFRP stands for Carbon-Fiberfor Carbon-Fiber Reinforced Polymers and they are one of the lightweight design Reinforced Polymers and they are one of the lightweight design secrets of the 700 hp super
secrets of the 700 hp super sports car, which now even comes withsports car, which now even comes with 750 hp in the new Superveloce version.
750 hp in the new Superveloce version. CFRP is the hi-
CFRP is the hi- tech heart of the intelligent lightweighttech heart of the intelligent lightweight design that is the key to maximum performance at Lamborghini design that is the key to maximum performance at Lamborghini .. The creation of the Aventador monocoque is a fusion of hi-tech The creation of the Aventador monocoque is a fusion of hi-tech and craftsmanship. Bathed in daylight, this production hall rou- and craftsmanship. Bathed in daylight, this production hall rou- tinely combines automated processes and highly specialized tinely combines automated processes and highly specialized manual skills. manual skills.
CARROZZERIA
CARROZZERIA
CARBONARA
CARBONARA
Photos Photos Bernhard Huber Bernhard Huber Text Text Michael Harnischfeger Michael Harnischfeger11
2
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133133 EncounterEncounter Smart Factory Smart Factory
The monocoque emerges from several components to The monocoque emerges from several components to form an extremely stiff single-shell cell. However, single-shell does form an extremely stiff single-shell cell. However, single-shell does not mean that the entire monocoque, weighing just 147.5 kilo- not mean that the entire monocoque, weighing just 147.5 kilo- grams, consists of just one
grams, consists of just one layer of carbon composite material. Thelayer of carbon composite material. The special jointing technology means rather that the individ special jointing technology means rather that the individ ual partsual parts are physically united to create a greater whole that will neither are physically united to create a greater whole that will neither twist nor bend, even when subjected to very
twist nor bend, even when subjected to very high loads, e.g. duringhigh loads, e.g. during extremely dynamic maneuvering or in the event of a collision. The extremely dynamic maneuvering or in the event of a collision. The roughly 20 pieces that make up the
roughly 20 pieces that make up the monocoque for the Aventadormonocoque for the Aventador and Aventador Roadster – including its
and Aventador Roadster – including its folding hardtop – are madefolding hardtop – are made using three different production processes, each
using three different production processes, each one guaranteeingone guaranteeing the perfect result for the
the perfect result for the respective demands.respective demands. Our tour brings us first
Our tour brings us first into prepreg production, a roominto prepreg production, a room of barely 400 square meters. The sliding doors open and close au- of barely 400 square meters. The sliding doors open and close au- tomatically because the material being processed here is highly tomatically because the material being processed here is highly temperature sensitive. “The carbon-fiber mats, which are preim- temperature sensitive. “The carbon-fiber mats, which are preim- pregnated with a thermoset liquid epoxy are delivered to us by our pregnated with a thermoset liquid epoxy are delivered to us by our supplier at a temperature of
supplier at a temperature of minus 21 degrees Celsius,” explains aminus 21 degrees Celsius,” explains a technician as he handles one of the slightly tacky layers, just a technician as he handles one of the slightly tacky layers, just a couple of millimeters thick. “But the material can only be processed couple of millimeters thick. “But the material can only be processed at plus 21 degrees Celsius, so it’s heated up before we start working at plus 21 degrees Celsius, so it’s heated up before we start working with it and then
with it and then maintained at a constant 21 maintained at a constant 21 degrees.degrees.”” A total of four layers,
A total of four layers, each with different characteris-each with different characteris- tics, are laid precisely by skilled hands i
tics, are laid precisely by skilled hands i nto the associated molds.nto the associated molds. The mats, which are delivered in large
The mats, which are delivered in large rolls, are precut to shaperolls, are precut to shape using CNC machines. The meticulous concentration on the part of using CNC machines. The meticulous concentration on the part of the specialists at work is palpable, yet it is paired with a certain the specialists at work is palpable, yet it is paired with a certain calm serenity that comes with expertise. It’s down to fracti calm serenity that comes with expertise. It’s down to fracti ons ofons of millimeters in a process with no room f
millimeters in a process with no room f or error. The top mat foror error. The top mat for the exterior roof skin and other sections has
the exterior roof skin and other sections has a paintable layer, asa paintable layer, as these are the surfaces that will later gleam in the car’s final color. these are the surfaces that will later gleam in the car’s final color. Lamborghini produced the female molds in-house. They are not Lamborghini produced the female molds in-house. They are not made from metal, but are likewise from carbon-fiber reinforced made from metal, but are likewise from carbon-fiber reinforced polymers. The benefit of this is that they need just a few hours to polymers. The benefit of this is that they need just a few hours to cool and are considerably lighter.
cool and are considerably lighter. Skill –
Skill –the shells of the under-sectionthe shells of the under-section are also laminated by are also laminated by hand. Theyhand. They are made using a process invented by are made using a process invented by Lamborghini and patented under Lamborghini and patented under the name RTM Lambo. the name RTM Lambo.
Pressure and heat –
Pressure and heat –the prepreg com-the prepreg com- ponents bake in the autoclave for ponents bake in the autoclave for three hours at 135 degrees Celsius three hours at 135 degrees Celsius in a vacuum of six bar. The flexible in a vacuum of six bar. The flexible mats fuse during this process to cre- mats fuse during this process to cre- ate a single hard piece. ate a single hard piece.
Upside-down –
Upside-down –the tub, the lowerthe tub, the lower section of the monocoque, is baked section of the monocoque, is baked in two molds. Between the CFRP in two molds. Between the CFRP mats is a layer of white epoxy foam. mats is a layer of white epoxy foam.
Precision is more important than Precision is more important than speed –
speed –the Aventador monocoque isthe Aventador monocoque is built largely by hand. built largely by hand. 4 4 5 5 6 6 7 7
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134The monocoque emerges from several components to The monocoque emerges from several components to form an extremely stiff single-shell cell. However, single-shell does form an extremely stiff single-shell cell. However, single-shell does not mean that the entire monocoque, weighing just 147.5 kilo- not mean that the entire monocoque, weighing just 147.5 kilo- grams, consists of just one
grams, consists of just one layer of carbon composite material. Thelayer of carbon composite material. The special jointing technology means rather that the individ special jointing technology means rather that the individ ual partsual parts are physically united to create a greater whole that will neither are physically united to create a greater whole that will neither twist nor bend, even when subjected to very
twist nor bend, even when subjected to very high loads, e.g. duringhigh loads, e.g. during extremely dynamic maneuvering or in the event of a collision. The extremely dynamic maneuvering or in the event of a collision. The roughly 20 pieces that make up the
roughly 20 pieces that make up the monocoque for the Aventadormonocoque for the Aventador and Aventador Roadster – including its
and Aventador Roadster – including its folding hardtop – are madefolding hardtop – are made using three different production processes, each
using three different production processes, each one guaranteeingone guaranteeing the perfect result for the
the perfect result for the respective demands.respective demands. Our tour brings us first
Our tour brings us first into prepreg production, a roominto prepreg production, a room of barely 400 square meters. The sliding doors open and close au- of barely 400 square meters. The sliding doors open and close au- tomatically because the material being processed here is highly tomatically because the material being processed here is highly temperature sensitive. “The carbon-fiber mats, which are preim- temperature sensitive. “The carbon-fiber mats, which are preim- pregnated with a thermoset liquid epoxy are delivered to us by our pregnated with a thermoset liquid epoxy are delivered to us by our supplier at a temperature of
supplier at a temperature of minus 21 degrees Celsius,” explains aminus 21 degrees Celsius,” explains a technician as he handles one of the slightly tacky layers, just a technician as he handles one of the slightly tacky layers, just a couple of millimeters thick. “But the material can only be processed couple of millimeters thick. “But the material can only be processed at plus 21 degrees Celsius, so it’s heated up before we start working at plus 21 degrees Celsius, so it’s heated up before we start working with it and then
with it and then maintained at a constant 21 maintained at a constant 21 degrees.degrees.”” A total of four layers,
A total of four layers, each with different characteris-each with different characteris- tics, are laid precisely by skilled hands i
tics, are laid precisely by skilled hands i nto the associated molds.nto the associated molds. The mats, which are delivered in large
The mats, which are delivered in large rolls, are precut to shaperolls, are precut to shape using CNC machines. The meticulous concentration on the part of using CNC machines. The meticulous concentration on the part of the specialists at work is palpable, yet it is paired with a certain the specialists at work is palpable, yet it is paired with a certain calm serenity that comes with expertise. It’s down to fracti calm serenity that comes with expertise. It’s down to fracti ons ofons of millimeters in a process with no room f
millimeters in a process with no room f or error. The top mat foror error. The top mat for the exterior roof skin and other sections has
the exterior roof skin and other sections has a paintable layer, asa paintable layer, as these are the surfaces that will later gleam in the car’s final color. these are the surfaces that will later gleam in the car’s final color. Lamborghini produced the female molds in-house. They are not Lamborghini produced the female molds in-house. They are not made from metal, but are likewise from carbon-fiber reinforced made from metal, but are likewise from carbon-fiber reinforced polymers. The benefit of this is that they need just a few hours to polymers. The benefit of this is that they need just a few hours to cool and are considerably lighter.
cool and are considerably lighter. Skill –
Skill –the shells of the under-sectionthe shells of the under-section are also laminated by are also laminated by hand. Theyhand. They are made using a process invented by are made using a process invented by Lamborghini and patented under Lamborghini and patented under the name RTM Lambo. the name RTM Lambo.
Pressure and heat –
Pressure and heat –the prepreg com-the prepreg com- ponents bake in the autoclave for ponents bake in the autoclave for three hours at 135 degrees Celsius three hours at 135 degrees Celsius in a vacuum of six bar. The flexible in a vacuum of six bar. The flexible mats fuse during this process to cre- mats fuse during this process to cre- ate a single hard piece. ate a single hard piece.
Upside-down –
Upside-down –the tub, the lowerthe tub, the lower section of the monocoque, is baked section of the monocoque, is baked in two molds. Between the CFRP in two molds. Between the CFRP mats is a layer of white epoxy foam. mats is a layer of white epoxy foam.
Precision is more important than Precision is more important than speed –
speed –the Aventador monocoque isthe Aventador monocoque is built largely by hand. built largely by hand. 4 4 5 5 6 6 7 7
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134134 EncounterEncounter Smart Factory Smart Factory 135135 EncounterEncounter Smart Factory Smart Factory
The perfect cell –
The perfect cell –after the final bake,after the final bake, the paintable top section and the the paintable top section and the lower section of the monocoque are lower section of the monocoque are united, giving a combined weight united, giving a combined weight of just 147.5 kilograms. of just 147.5 kilograms.
Clever solution – Clever solution –the CFRP moldsthe CFRP molds are lighter than those made from steel are lighter than those made from steel and they also cool down and they also cool down faster.faster.
It has to be perfect – It has to be perfect – wearing wearing breathing masks, technicians remove breathing masks, technicians remove the tiniest edges and irregularities. the tiniest edges and irregularities.
Growth –
Growth – technicians assemble technicians assemble the front and rear subframes onto the the front and rear subframes onto the monocoque to create, in this case, monocoque to create, in this case, a Roadster.
a Roadster.
Once the prepreg layers are lying correctly in their Once the prepreg layers are lying correctly in their mold, they are covered with a blue protective sheet, a soft, white mold, they are covered with a blue protective sheet, a soft, white felt layer and a shimmering violet sheet of foil. When the pipes felt layer and a shimmering violet sheet of foil. When the pipes then generate a vacuum to suck out every last air bubble, the then generate a vacuum to suck out every last air bubble, the package looks almost like a cryptic installation by artist Christo. package looks almost like a cryptic installation by artist Christo. Finally, they wait on carts to be rolled into one of the three auto- Finally, they wait on carts to be rolled into one of the three auto- claves not far from the
claves not far from the exit of the small, exit of the small, hi-tech department. Oncehi-tech department. Once