TechDay Lightweight Design

1. Lightweight engineering with carbon-fiber technology

Lamborghini is redefining the future of the super sports car with

expertise unparalleled worldwide

• Systematic lightweight design concept for extreme dynamics and

outstanding efficiency

• Full monocoque for the new V12 model with exceptional characteristics

• Worldwide leading know-how in development, production and

application of carbon-fiber materials

• New production system uses innovative technologies to the highest

quality standards

• Investments in carbon fiber demonstrate the innovative strengths and

forward-looking power of the brand

Lamborghini is heading into the future with a systematic lightweight design

concept – the intensive application of carbon-fiber materials forms the key

foundation for the extreme dynamics and less emissions that will define its

future super sports cars. The new V12 model that will debut at the 2011 Geneva

motorshow is based on a full monocoque construction made from innovative

carbon-fiber technology and superior to anything else on the market –

developed and produced entirely by Automobili Lamborghini.

This development sees Lamborghini once again demonstrate its worldwide

leading expertise in carbon-fiber reinforced plastics (CFRP) technology. The

super sports car brand from Sant’#### Bolognese is the only automaker to

have fully mastered the extensive CFRP process across a range of

technologies in-house – through design, simulation, engineering, prototyping,

testing, validation and production, using state-of-the-art industrial processes

to the very highest quality standards. Lamborghini is putting its innovative, inhouse

developed and patented technologies into series production for the first

time with the successor to the Murciélago.

“Systematic lightweight engineering and an optimum power-to-weight ratio

are absolutely crucial to the super sports cars of the future, for both the

highest levels of driving pleasure and lower emissions,” says Stephan

Winkelmann, President and CEO of Automobili Lamborghini. “Lamborghini has

put a lot of hard work into growing its expertise in the application of CFRP,

attaining the leadership position we hold today. With its innovative carbon3

fiber monocoque, the successor to the Murciélago displays the full

competence of our brand and starts a new chapter in the history of

Lamborghini.”

Technology transfer between Audi and Lamborghini

Automobili Lamborghini is a 100 percent subsidiary of AUDI AG and makes

extensive use of the Audi brand’s renowned, world-leading expertise in

lightweight engineering. Audi is particularly advanced when it comes to the

high-volume application of aluminum, which Lamborghini uses in areas such

as the space frame construction of the Gallardo model range.

In the field of fiber-reinforced composite materials, the competences of Audi

and Lamborghini are perfectly balanced – Lamborghini’s contribution to the

partnership includes decades of experience with carbon fiber and know-how in

the development and production of low-volume models, while Audi is working

with a number of lightweight materials on an intelligent hybrid construction

concept. The fundamental thinking is the same for both brands – every future

model generation must be considerably lighter than its predecessor.

Full monocoque for the new V12 supersportscar

Lamborghini’s flagship is made of a full monocoque. In contrast to some

competitors, the entire occupant cell – the tub and roof – is one single physical

component. This ensures extreme rigidity and thus outstanding precision on

the road, as well as an extremely high level of passive safety for the driver of

the new super sports car and his passenger. The entire monocoque weighs in

at only 147.5 kilograms (324.5 lbs).

The pushrod suspensions, the twelve-cylinder engine and the innovative,

super-fast shifting ISR transmission are all connected to the monocoque via

aluminum sub-frames front and rear. This lightweight design features an

impressive combination of extreme rigidity and very low weight.

The entire chassis of the future V12 model boasts an enormous static torsional

stiffness of 35,000 Newton meters per degree. Yet the whole body-in-white

weighs only 229.5 kilograms (504.9 lbs) – a best-in-class for a super sports car

with a stunning power output of 515 kW / 700 hp.

Completely new facility for carbon-fiber vehicles

A completely new 5400 sq. meter production facility has been built in

Sant’#### for the innovative monocoque and the complete body-in-white of

the Murciélago successor. A state-of-the-art process combines automated

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production with meticulous craftsmanship to create carbon-fiber structures of

the very highest quality and precision. Major elements of the monocoque are

produced using Lamborghini’s patented “RTM-Lambo” technology. This

process does not necessitate the laborious use of hand lamination and

autoclave, and at the same time uses production molds made from carbon

fiber, making RTM-Lambo a significant step forward in production technology.

One figure in particular illustrates the importance of carbon-fiber technology

to Lamborghini – 2009 saw around 100 tonnes of carbon-fiber materials used

in production, a figure that will triple to more than 300 tonnes by 2013.

The optimum lightweight design strategy for every model

With the successor to the Murciélago, Automobili Lamborghini is implementing

across its entire model lineup an optimum lightweight design strategy based

on the respective vehicle and volume. The most important base material

alongside carbon fiber is aluminum, where Lamborghini benefits from the

leading lightweight engineering expertise possessed by the Audi brand. The

Gallardo range, for example, is built using Aluminum Space Frame technology,

complemented by the targeted application of carbon-fiber components. With a

dry weight of only 1,340 kilograms (2,948 lbs), the Gallardo LP 570-4

Superleggera is the most lightweight super sports car in its class.

High level of investment in future technology

Automobili Lamborghini embarked upon a program of extensive investment in

its preparations for the next technological leap to a complete carbon-fiber

monocoque. The super sports car brand is now driving forward technology

development in two in-house research centers, the Advanced Composite

Research Center (ACRC) in Sant’#### Bolognese and the Advanced

Composite Structures Laboratory (ACSL) in Seattle, USA.

Partners in the intensive research and development cooperation include

aerospace giant Boeing, the University of Washington and golf equipment

manufacturer Callaway. A host of patents for materials, as well as design,

bonding and production technologies, document the innovative spirit of the

Italian brand. The clear commitment to carbon-fiber technology is also a major

factor in Lamborghini’s preparedness for the future.

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1.1. The manifesto for super sports cars of the future

Stephan Winkelmann,

President and CEO of Automobili Lamborghini SpA:

“Lamborghini stands for extreme and uncompromising super sports cars in

the best Italian tradition. For Lamborghini, however, innovation has always

been part of that tradition. The time has come for us to redefine the future of

our super sports cars.

Obviously, the focus is on our customers’ two most important purchasing

criteria – design and performance. Design has always been the number one

reason for wanting to own a Lamborghini – and that’s not going to change. We

will ensure that a Lamborghini will always remain unique and clearly

recognizable.

Performance, on the other hand, is something that will be extensively

redefined. Just a few years ago, the most important aspects were top speed,

acceleration and handling – in that order of priority. However, things have

changed since then.

Together with design, handling and acceleration have become increasingly

important. Top speed is no longer as decisive, because all super sports cars

can manage more than 300 km/h (188 mph) – a speed that can barely be

attained on the race track, and that is out of the question on the public roads

of most countries on earth. Nowadays, the issues of handling and acceleration

are far more crucial to consistent driving fun.

The power-to-weight ratio is the key factor in the improvement of both and in

the experience of more direct driving fun. This means that increased power is

no longer the focal point – because we no longer need to achieve higher top

speeds, and because CO2 emissions are relevant for super sports cars, too.

This means that weight must be reduced.

It is important to understand how best to approach this reduction. Since the

1980s, the average weight of our vehicles has increased by around 500

kilograms (1,100 lb), due to the requirements set by safety, comfort and

emissions reduction. This is a trend that we must reverse with urgency.

However, because cannot sacrifice either safety or comfort, we will start using

new materials.

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The magic words are carbon fiber. We already began working with this in

Sant’#### Bolognese more than 30 years ago. We now have two research

laboratories in Sant’#### Bolognese and Seattle, and we have mastered a

host of technologies that put us in a clearly dominant position when it comes

to low-volume series production. With our new plant for building carbon-fiber

monocoques and complete carbon-fiber bodyshells, we are delivering the

highest quality levels and absolute precision.

Every new Lamborghini will make use of this carbon-fiber technology for

optimum weight reduction. 2011 will see the new Lamborghini V12

supersportscar launch a whole new chapter in the history of the brand.”

2. The innovative monocoque of the new V12 model

Carbon composite materials are a key technology for the automotive

engineering of tomorrow, especially for high-performance sports cars. These

materials made from CFRP combine the lowest possible weight with excellent

material characteristics – they are very light, extremely rigid and exceptionally

precise.

Furthermore, CFRP materials can also be formed into highly complex

components with integrated functions. This reduces the number of individual

parts when compared to traditional metal construction – thus enabling further

weight reduction. Lighter cars have lower fuel consumption and fewer CO2

emissions. Most significantly, however, it improves the power-to-weight ratio –

the deciding factor in the overall feel and performance of a sports car. A super

sports car built using CFRP accelerates faster, has superior handling and

better braking.

Monocoque makes the most of material characteristics

The cell of the future Lamborghini flagship super sports car is made entirely

from carbon fiber and has been designed as a monocoque structure. The

load-bearing structure of the vehicle is engineered as a “single shell” that

functions physically as one component, thus taking full advantage of the

extreme rigidity of CFRP. Formula 1 race cars have been built using CFRP

monocoques for many years – and have proven their crash worthiness time

and again. The same applies to road-going sports cars featuring monocoque

technology – the carbon fiber occupant cell functions like an extremely safe

roll cage.

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Construction offer many advantages

Of course, the term “single shell” applies only in the descriptive sense – the

new Lamborghini monocoque is made from a series of individual parts with

specific functions, such as stiffening elements made from Braiding technology,

that is one of the best technology to manage energy adsorption in case of

crash. After the curing process, however, this structure functions as a single

component – including the base section known as the tub and the complete

roof.

The full monocoque solution offers advantages which other processes, like a

tub where a metal roof structure is attached in a conventional manner, cannot

realize. That’s why Lamborghini made the no compromise choice of the full

monocoque, which weighs only 147.5 kilograms (324.5 lbs).

Extremely rigid construction

Superior passive safety is only one benefit of the extreme rigidity of a full

carbon fiber monocoque - very high torsional rigidity is another. The

monocoque is connected at the front and rear with equally rigid aluminum

sub-frames, on which the suspension, engine and transmission are mounted.

The entire body-in-white of the future V12 model weighs only 229.5 kilograms

(505 lbs) and boasts phenomenal torsional stiffness of 35,000 Newton meters

per degree. This guarantees a superb feeling of solidity, but, more importantly,

extremely exact wheel control with excellent steering precision and sensitive

feedback. For the dedicated driver, both are essential for truly enticing driving

pleasure. The new Lamborghini flagship responds to the most minute steering

input with the stunning precision of a perfectly balanced race car.

Depending on the form, function and requirements of the individual elements,

the Lamborghini development team selected from three main CFRP

manufacturing methods within its technology tool kit. They differ not only in

their production processes, but also in the type of carbon fiber and its weave

and, most importantly, in the chemical composition of the synthetic resin

used.

Resin Transfer Moulding (RTM): In this process the carbon fiber mats are

preformed and impregnated with an exact amount of resin. Afterwards, they

are cured under heat while the part is in the mold. Lamborghini has achieved a

major breakthrough by further developing this method. Using the patented

“RTM-Lambo” process, the final mold is no longer a heavy, complex metal

piece, but is made instead from lightweight carbon-fiber parts, thus making

the manufacturing process faster, more flexible and more efficient. An

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additional benefit of the RTM-Lambo process is the low injection pressure that

doesn’t require expensive equipment.

Prepreg – The carbon fiber mats used in this method, commonly known as

prepreg, are pre-injected by the supplier with a thermosetting liquid resin and

must be stored at a low temperature. The mats are then laminated in molds

and cured under heat and pressure in an autoclave. Prepreg components are

complex to make, but have an extremely high-quality surface finish (Class-A

surface quality) and are therefore the preferred option for use in visible

locations.

Braiding – These components are manufactured by using RTM technology.

This carbon fiber weave technology is derived from the textile industry and

used to make tubular components for special applications such as structural

roof pillars and rocker panels. The woven components are made by diagonally

interweaving the fiber in several layers.

The monocoque of the new V12 super sports car is constructed using these

technologies applied in a series of special processes. One significant

advancement Lamborghini realized is the ability to use already-assembled

monocoque elements as the mold for the next step in the process. This makes

for a considerable simplification of the manufacturing process compared with

conventional methods.

Epoxy foam components are also used within the monocoque. They are

placed in strategic points to increase the stiffness of the monocoque by

working as spacers between the composite layers while also dampening noise

and vibration. In addition, aluminum inserts are laminated into the front and

rear surfaces to facilitate connection with the aluminum front and rear subframe

elements.

Because of the complexity of the materials and process outlined above,

Lamborghini decided to produce its new monocoque completely in-house,

managing one strategic step in the production process.

Quality control is an absolutely crucial factor – every single monocoque is

measured to exacting tolerances of only 0.1 millimetres, facilitating the

extreme precision of the overall vehicle. Quality control starts with the

purchase of the carbon fiber parts. Every delivery of carbon fiber is certified

and the material is checked regularly for compliance with quality standards.

Lamborghini worked together with its suppliers to develop a world-exclusive

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fiber and resin system for its RTM technology. Ultimately, these materials and

processes constitute an important part of Lamborghini’s worldwide leading

expertise in the field.

2.1. The new Lamborghini CFRP production facility

Lamborghini has achieved an impressive level of innovation not only in the

design and development of carbon-fiber structures, but also in the associated

production technology. For the future twelve-cylinder flagship and its

monocoque bodyshell made from carbon-fiber reinforced plastic, a brand new

production facility was built at company headquarters in Sant’####

Bolognese. Every single production step from receipt of the fiber mat rolls to

completion of the paint-ready bodyshell is carried out in-house.

The new production facility is organized in five lines :

1. The prepreg parts are made on the first line. They meet extremely high

demands for stiffness and surface quality, but require a high level of

manual labor and must be cured in an autoclave under heat and

pressure.

2. On the second line, parts and sub-assemblies are made using resin

transfer molding (RTM) technology. This process is highly automated.

The autoclave is not required, with curing taking place in a heated

chamber. This is also where the prepreg parts from the autoclave and

the epoxy foam parts are integrated into the RTM monocoque

structure.

3. The third line is where the epoxy foam stiffening components are

produced. The same components are then assembled as inserts into

the pre-preg and RTM process

4. On the fourth line the monocoque structure and the roof are fully

machined, assembled together and measured.

5. On the fifth line, the finished monocoque is precisely connected to the

aluminum front and rear sub-frames and all exterior bodyshell parts to

create the finished bodyshell.

The prepreg line starts with the automated cutting of the parts. The

computer-controlled cutting machine ensures maximum precision, as well as

minimum cutting strokes and waste. The machine is located in a climatecontrolled

room, because the prepreg materials must be maintained at a low

temperature until the final stage of the process. The subsequent laminating

work carried out on the prepreg parts is handled by highly experienced

specialists. They create the complex forms and ensure the highest possible

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aesthetic quality of the finished product. After a vacuum bagging process, The

final curing takes place in two autoclaves. They operate at a pressure of 6 bar

and a temperature of 135 degrees Celsius.

The RTM line commences once the dry fiber patches have been cut, with the

automated pre-forming of the parts. The fiber mats are formed in a press –

similar to the sheet metal presses used in conventional bodyshell

manufacture. This technology enables complex structures to be produced to

an extremely high level of precision. The final positioning process carried out

on the parts is handled by lasers, where the pre-formed parts are are joined

together in their final form on the tooling .Once the tooling is closed, the resin

injection starts followed by curing at around 100 degrees Celsius.

Using the patented RTM-Lambo technology, the moulds are made from carbon

fiber instead of steel – in some cases, the component just completed serves as

the “mould” for the next step in the process, to which the additional parts are

simply added and co-cured. A tolerance of only 0.1 millimeters applies

throughout.

On the assembly line, the monocoque is connected to the aluminum subframes

and all additional parts ranging from the front spoiler to the rear

diffuser. At this point, every vehicle is measured in its entirety; the automatic

precision measuring system works partly with lasers and partly by touch.

Surface quality is ultimately checked in a light tunnel by highly-trained

specialists. Finally, the body-in-white is signed off for painting and for full

vehicle assembly.

 

 

3. Lamborghini’s CFRP expertise

Lamborghini possesses many years of expertise in carbon-fiber reinforced

plastics technology (CFRP). The super sports car brand from Sant’####

Bolognese is the only vehicle maker to have mastered the entire CFRP process

across several technologies in-house – from 3D design, through simulation,

test, production and validation, all in a state-of-the-art industrial process to

the very highest quality levels. Lamborghini has around three decades of

experience with this hi-tech material. The early eighties saw the production of

its first prototype carbon-fiber bodyshell. Carbon-fiber reinforced plastics

have been used in the brand’s series production models since 1985, with their

proportion growing continually every since.

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Dedicated work on innovative methods

The company is now working hard to expand its worldwide leading position –

at the new Advanced Composite Research Center at company headquarters in

Sant’####, company engineers and technicians are working on innovative

design and production methods for carbon-fiber applications in automotive

engineering. At the Lamborghini Advanced Composite Structures Laboratory

at the University of Washington, the behavior of these materials is being

researched and tested under everyday conditions and crash situations, with

input from a wide range of cooperation partners. Finally, the innovative

monocoque and the entire bodyshell of the Murciélago successor are being

produced at the expansive new carbon fiber production facility in Sant’####

Bolognese.

3.1. The Advanced Composite Research Center (ACRC)

The ACRC research and development center places Lamborghini at the very

top when it comes to the research of innovative materials and new methods

for low-volume production. More than 40 experts work here to develop vehicle

components of all shapes and sizes. These specialists build prototypes and the

associated tooling, and derive concepts for optimum production methods.

They also develop the appropriate repair techniques for CFRP structures. One

major focal point is simulation technology – an especially complex topic when

it comes to carbon fiber. With sophisticated systems developed largely inhouse,

engineers can reliably and precisely calculate the technical

characteristics and crash behavior of CFRP components. A host of patents

document the creativity and innovation of the development work being

carried out by Lamborghini.

The ACRC comprises two facilities on the factory site in Sant’####. In the

“Prepreg Center”, conventional production methods using autoclaves are

perfected, while, at the so-called “Out of Clave Center”, work is focused on

innovative technologies that do not require the use of large-scale autoclaves.

One technology developed here includes the patented “RTM-Lambo”

production process.

Cooperation with partners from science and industry

Core to the development work carried out at the Lamborghini Advanced

Composite Research Center is the cooperation with highly competent partners

from science and industry. In 2010, a partnership was agreed between

Lamborghini, aircraft manufacturer Boeing and the University of Washington

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in Seattle. One research topic is new kinds of repair technologies for complex

carbon-fiber structures. The partners are working on further topics such as

wireless temperature sensors that are bonded into the fiber structures.

Forged Composite a next-generation material

Lamborghini is also securing its leading position in the application of carbon

fiber well into the future. Engineers at the ACRC are working with the very

latest equipment – including a heated 1000-tonne press – on technologies for

use on the vehicle generations of tomorrow and beyond. Forged Composite®

is the keyword for the lightest, most stable and most precise material used todate.

In contrast to conventional CFRP materials based on long, interwoven fibers,

this revolutionary material is made from 1-2 inch short fibers. More than

500,000 braided fibers per square inch create a material that has only one

third of the density of titanium, yet is considerably stronger. Thanks to an

innovative forging process, Forged Composite can be formed very efficiently

and to the highest levels of precision.

Lamborghini offered a first glimpse of the outstanding characteristics of

Forged Composite with the Sesto Elemento prototype. Its monocoque and

parts of its suspension are made from Forged Composite. However, there is

still development work that remains to be done before this material can be

used in series production.

Automobili Lamborghini’s partner in the development of Forged Composite is

Callaway Golf Company, the world’s leading manufacturer of golf equipment.

Callaway uses Forged Composite to produce club heads with vastly superior

characteristics than those made using conventional metal alloys.

3.2. The Advanced Composite Structures Laboratory (ACSL)

The Lamborghini Advanced Composite Structures Laboratory (ACSL) at the

University of Washington in Seattle, USA is another element in the extensive

investment made by Automobili Lamborghini in carbon-fiber technology. Since

2007, Lamborghini has been providing the laboratory with substantial

funding, thus supporting long-term research work at the university. The ACSL

has borne its name since 2009.

One of the main tasks of the laboratory is its work as the hub for all

Lamborghini’s cooperation partners in the USA, such as Callaway Golf and

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Intel. Further partners in the joint programs are aircraft manufacturer Boeing

and the American Federal Aviation Administration (FAA). Boeing in particular

possesses an enormous amount of expertise in the field, with the new Boeing

787 Dreamliner being the first commercial airliner to feature a fuselage made

from carbon-reinforced plastic.

One focal point of the work done at the ACSL is material analysis and

simulation. The crash behavior of composite structures in an automobile was,

for example, the subject of a core research project. A key term in materials

research and simulation technology is the Building Block Approach.

This technique sees small samples of new materials tested and defined in

minute detail. As soon as the material and its characteristics are perfectly

understood, a slightly larger test piece is made and tested again. At a later

point, an entire component 1:1 scale is made using this material and tested. As

in a building block system, the simulation is always calibrated with the real

crash test case, in order to have an excellent level of predictability in the 1:1

real crash test. Further down the line, of course, real prototypes are also

destroyed in the real crash test facility – although only to validate findings.

Lamborghini and its cooperation partners like Boeing now find themselves in

the final years approaching a major breakthrough. With the Building Block

Approach, complete crash simulation is also possible with a CFRP structure.

Boeing uses the same methodology for the development of commercial

aircraft - the 787 was validated using this simulation method.

3.3. Patents, partners and repair technology

Naturally, even a super sports car can meet with the occasional accident or

misfortune, which is why Lamborghini has taken the necessary precautions –

with a dedicated repair concept and a small team of specially selected and

trained experts, a damaged Lamborghini is in excellent hands. These “flying

doctors” support Lamborghini service centers on site in assessing the

damage, and then handle repairs to the carbon-fiber structure themselves.

The Lamborghini promise is that the repaired area is 100 percent the same

quality as the original part.

Smaller damages to the carbon-fiber exterior of a Lamborghini model such as

this are generally unproblematic – add-on components are easy to replace.

What is considerably more troublesome is damage to the load-bearing

structure of the super sports car – this calls for highly specialist know-how,

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because the extent and implication of the damage can only truly be assessed

by absolute experts.

For this reason, Lamborghini service centers do not carry out this kind of work

themselves; the repair expertise rests with the Lamborghini Advanced

Composite Research Center (ACRC). The dealer only photographs and

documents the damage and sends his findings to the ACRC in Sant’####

Bolognese, where the experts evaluate the information.

Certificate guarantees 100 percent quality

In the event of a structural damage, one of the flying doctors gets on the next

plane with his tool kit. In the service center workshop, the flying doctor uses

his NDI (Non-Destructive Inspection) equipment to assess whether, alongside

the visible damage, there are any hidden cracks in the carbon-fiber structure.

He will then carry out a professional repair that fully reinstates the physical

performance of the structure – something that is also confirmed for the

customer by means of a certificate.

The idea for the flying doctor program was created through the cooperation

with Boeing. The aircraft company has been working for some time with this

kind of traveling specialist and has developed a system that enables carbonfiber

repairs to be carried out perfectly using a very compact set of

equipment. At Lamborghini, the system was further developed to suit the

requirements of automotive technology and then applied to the benefit of the

customer.

A host of patents for innovations

The repair process is one further element in the extensive carbon-fiber

competence possessed by Automobili Lamborghini. Naturally, the leading

expertise developed by the brand from Sant’#### can also be found in a host

of patents. They apply to such innovations as the RTM-Lambo production

process, the monocoque assembly concept, the system used to connect the

CFRP structure to the metal components, the self-heating tools used in the

RTM process, the bodyshell of the Sesto Elemento concept car and its unique

paint finish and to Radicarbon, an adaptation of Forged Composite. Further

patent submissions are currently undergoing the registration process and

apply to future developments.

The partners – the best from all fields

Automobili Lamborghini is working on the further development of carbon-fiber

technology together with the most renowned of partners. The hubs of

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activity in this know-how network are Lamborghini’s two research and

development centers, the ACRC and the ACSL. The most important partners

are the University of Washington, Boeing and Callaway Golf.

The University of Washington in Seattle was founded in 1861and is one of the

foremost universities in the USA. Due to its proximity to world-leading aviation

firm, the Boeing Company, the University of Washington possesses particular

expertise on all areas associated with aeronautics and carbon-fiber

engineering. The head of the Automobili Lamborghini Advanced Composite

Structure Laboratory based here is Professor Paolo Feraboli, who has been in

close contact with the engineers in Sant’#### for many years.

The Boeing Company is the world’s largest manufacturer of commercial and

military aircraft. Founded in 1915, the company grew during the 40s to become

an important military aircraft manufacturer. Its development into the leading

producer of passenger aircraft was closely linked to the development of the

Boeing 707 and later the Boeing 747. The Boeing 787 Dreamliner, which is

currently under development, is the world’s first high-capacity airplane with a

fuselage built almost entirely from carbon-fiber reinforced plastic. This has

given Boeing the most extensive experience in the simulation, development

and manufacture of CFRP structures

Callaway Golf, on the other hand, is the world’s leading company in a

completely different sector – golfing equipment. The Callaway Golf Company

produces and sells golf clubs and golf balls and sells golfing attire, shoes and

accessories under a number of different brands in more than 110 countries

worldwide. In striving continuously for innovation, the Callaway Golf Company

develops products that can improve the performance and skill of every golfer.

For the engineers at Callaway, the application of carbon-fiber composite

materials instead of steel and titanium offered the chance to develop

advanced club heads that enable better transmission of force to the ball and

more precise trajectories. The “Forged Composite” developed through the

joint efforts of these two research and development teams is the first result

achieved by the cooperation of Callaway and Lamborghini.

3.4. 30 years of experience with carbon fiber

Automobili Lamborghini has around 30 years of experience with fiberreinforced

plastics. As far back as 1983, engineers in Sant’#### built a

prototype of the legendary Countach using an occupant cell made entirely

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from CFRP – a sensational pioneering achievement at the time. The 490 hp

V12 was put through its paces in extensive test driving and demonstrated

impressive dynamics due to its weight advantage. This one-off finally met its

end in a crash test – the automotive industry’s first crash test with a carbonfiber

road-going sports car.

For Lamborghini, this marked an impressive demonstration of its role as a

pioneer in fiber-reinforced plastics – series production of the complete vehicle

was, however, not feasible at the time. It was in 1985 that the first

components made from glass-fiber reinforced plastics made it into series

production – the front hood and engine cover of the Countach Quattrovalvole

were made from this material.

Carbon-fiber structural parts in the Diablo

Lamborghini made a major technological leap in 1990 with the presentation of

the Diablo – this marked the first significant application of carbon fiber, and

not just for virtually all the exterior panels, but also in the bodyshell structure.

An underbody/tunnel component made from CFRP provided stiffening for the

tubular steel structure. The proportion of glass and carbon fiber grew

substantially in the 1993 Diablo Roadster – with the entire exterior skin, the

hard top and the spoiler made from fiber-reinforced plastic.

Systematic development in the Murciélago

The 2001 Murciélago brought with it the next step in the Lamborghini

lightweight philosophy. The center tunnel, substantial parts of the underbody

and the wheel arches were made from CFRP and provided additional stiffening

to the tubular steel structure. With the Murciélago Roadster came further

subassemblies, such as the structural framework around the driveline.

The highly exclusive limited-edition Reventón super sports car and Reventón

Roadster from 2008 and 2009 would not have been possible without the

extensive application of carbon-fiber technology. Here, too, all exterior panels

and significant parts of the bodyshell structure were produced in CFRP.

Preeminence in the Gallardo Superleggera

The current Gallardo LP 570-4 Superleggera and Gallardo LP 570-4 Spyder

Performante demonstrate how the targeted application of carbon fiber can

make an already excellent lightweight design even better. Thanks to its

intelligent aluminum structure, the complete Gallardo model range is already

among the most competitive in the super sports car sector when it comes to

power-to-weight ratio. Yet it was possible to improve even on this figure –

17

with a dry weight of only 1,340 kilograms (2,948 lbs), the Superleggera is the

undisputed best-in-class.

The weight reduction of 70 kilograms for the Superleggera compared with the

already incredibly lean Gallardo is due largely to the targeted application of

carbon-fiber components on the bodyshell and in the interior. The engine

bonnet of the Gallardo Spyder and Gallardo Spyder Performante is the

automotive industry’s largest carbon-fiber component with class A surface

quality.

In 2011, the successor to the Murciélago will see Lamborghini begin a new

chapter – for the very first time, a full monocoque structure made from carbon

fiber will form the basis for a super sports car bearing the sign of the bull.

Nice 007!

 

I remember the days not that long ago when all we wanted for the Murcie-successor was a carbon chassis...we're like spoiled kids, never happy.

Thank you 007.

Lamborghini is heading in the right direction, I can't wait to see the LP700.

I hope we will soon find out about the Gallardo replacement.

It looks like lamborghini is getting a lot of LUV !!

 

Thanks 007!! :eusa_clap:

dam great stuff! i knew they wouldnt fall behind. i have faith!!!!!

oooooooh how cute, they learned how to lay carbon fiber...

Way neat... Thanks for the details and pics, 007.

 

At each introduction, the various manufacturers and their partners claim to have developed a stronger, faster, and cheaper method of bringing C.F. to market.I'm curious to see how BMW mass produces C.F., presumably tubbed or, at the very least, C.F. intensive. It looks at though they will be the first to do so on a large scale with the "i" badged battery/hybrid models.

 

Very exciting times indeed with hope for a trickle down carbon intensive d.d.!

Forged CF. Sounds good.

why are there women in the factory ?

why are there women in the factory ?

 

They have skilled hands and they work more precisely than men when weight is not an issue.

Thats where all the profits from the various gallardo platform went to.

why are there women in the factory ?

 

You didn't just say that..

 

I am starting to paint a picture of you in my head and it ain't pretty.

^dude relax. dont paint any pictures. its a forum. jokes are no good with you ?

How about a nice Zund G3 cutter instead of those heavy-duty shears?

^dude relax. dont paint any pictures. its a forum. jokes are no good with you ?

 

Steve...you are best seen and not heard if your last 20 posts are any guide to your comment quality. I think you may need better material.

 

Not an insult, we all have our weaknesses. Like for instance, I can't sing.

 

Go back to lurking for us so I don't have to gouge my eyes out every time I see your name and words.

Thanks for the pictures! Factory looks unbelievably clean!

Thanks for the pictures! Factory looks unbelievably clean!

 

Welcome back, and where have you been?

 

 

Great info. as usual 007, thanks!

^dude relax. dont paint any pictures. its a forum. jokes are no good with you ?

 

I will never take that comment as a joke, the picture is painted, one sentence that showed your true character.

 

I certainly hope you have more respect for the women in your life.