Lamborghini has
just opened its new Advanced Composites Research Center (ACRC)
at its headquarters in Sant’Agata Bolognese, Italy. The
new center will now carry out research on innovative
design and production methods relating to carbon-fibre elements.
Both the ACRC
and an all-new production process for extremely complex
carbon-fibre structures now in place have been developed at the same
time. The process is secured through an array of patents
and constitutes a breakthrough into the next generation
of carbon-fiber components.
“The consistent development of carbon-fibre technology
is a key element of our strategy,” says Stephan
Winkelmann, President and CEO of Automobili Lamborghini
S.p.A. “The most important parameter for super
sportscars is, now as in the future, the weight-to-power
ratio; therefore, as there is a limit to power increase
due to emission regulations, we must work on weight
reduction. Extensive use of carbon fibre, even at
structural level, allows Lamborghini to be at the
forefront of development techniques. The real difference
is in the correct use of technologies and materials to
satisfy technical and financial concerns. This is what
the Center is all about.”
Key technology
Carbon composite materials are crucial to tomorrow’s
automotive engineering, especially for high-performance
sports cars. These materials are made from carbon-fiber
reinforced polymers and combine the lowest possible
weight with excellent mechanical properties. Cars become
lighter, thus improving fuel consumption and CO2
emissions. The decisive factor for any sports car is
improving its power-to-weight ratio and thus its
performance. A car built using composite materials in
carbon-fibre has improved acceleration and braking as
well as superior handling.
Gallardo LP 570-4 Superleggera: lightweight
engineering champion thanks to carbon fibre
The Lamborghini Gallardo LP 570-4 Superleggera, launched
earlier this year at the Geneva Motor Show,
offers a perfect example: compared with the Gallardo LP
560-4, its weight has been trimmed by a further 70
kilograms. One major contributing factor has been the use of exterior and interior
components made from carbon fibre. The sports car weighs in at no more than 1340
kilograms.
Over thirty years of experience at Lamborghini
Lamborghini has many years’ experience in composite
elements. The first carbon-fibre based chassis prototype
was built for the Countach as far back as 1983. Series
production parts first appeared in 1985. The current
Lamborghini Murciélago is built largely of carbon-fibre,
with 93 kilograms of structural carbon-fibre materials
in its bodyshell. The Gallardo Spyder’s engine cover is
the largest component ever produced in the automotive
world with RTM technology and a class-A surface optimum
finish.
ACRC’s functions
The new Lamborghini Advanced Composite Research Center
comprises two facilities covering an area of more than
2,600 square meters. A team of 30 people, engineers and
technicians, works here to develop vehicle components of
all shapes and sizes. They build prototypes and the
associated tools, production tools, and develop
optimised production technologies. Sophisticated systems
largely developed in-house allow extremely high
precision levels as engineers simulate manufacturing
processes as well as carry out crash tests on complex
carbon-fibre structures.
Focus on innovative technologies
The ACRC is fitted with state-of-the-art equipment, such
as a test laboratory with sophisticated testing and
measuring devices, automated cutting and casting
equipment, a heated, 1,000 ton press and several
autoclaves to harden carbon-fibre parts under high
pressure and temperatures. Efforts focus, however, on
“out of autoclave” technologies such as Resin Transfer
Molding (RTM), whereby carbon-fibre structures are
compressed under high pressure; or vacuum RTM, whereby
resin is forced into carbon-fibre using negative
pressure.
Breakthrough on production processes
Lamborghini ACRD’s specialists have already achieved a
definitive breakthrough with the invention of an
innovative technology: they have developed one new
process which combines the benefits of existing methods.
Thanks to the extensively patented “RTM light” process,
Lamborghini can use minimal pressure and relatively low
temperatures to manufacture carbon-fibre components to
the highest levels of quality, precision and surface
finish, from small parts to complex vehicle structures.
Further benefits include higher process speeds, lower
costs, and extremely light tooling.
World-leading expertise in crash simulation
Carbon-fibre materials have impressive advantages.
However, exceptional levels of expertise are necessary
in order to muster fully their application as, for
instance, in crash simulation. Together with The Boeing
Company, Lamborghini initiated a crash analysis research
program in 2007. In 2009, the Automobili Lamborghini
Advanced Composite Structures Laboratory (ACSL) was
established at the University of Washington, with Boeing
and other US companies as partners. Around 20 scientists
work in the fully-equipped laboratory and support the
team in Sant’Agata Bolognese primarily in the field of
crash and dynamics analysis. Results so far achieved
have delivered extensive benefits to Lamborghini cars’
safety and build quality.
