• Feb 14th 2011 at 8:28AM
  • 19
Lamborghini Aventador carbon fiber monocoque - Click above for high-res image gallery

The engineers at Sant'Agata have been so kind as to give the world a glimpse of the carbon fiber reinforced polymer monocoque that will eventually serve as the backbone for the Aventador LP700-4. Using the high-tech (and similarly high-dollar) material should serve up some serious rigidity while keeping weight as low as possible at the same time. Lamborghini says that the entire body structure of the Aventador will hit the scales at an incredibly light 505 pounds, and that the monocoque you see above will make up just 324.5 pounds of that figure.

While using CFRP for a vehicle's body structure is nothing new, Lamborghini says that it has taken the process one step further by making the body molds themselves out of carbon fiber instead of the typical metal. We can't imagine that the change will make a whole heck of a lot of difference in the final product, but it's interesting to know that there's carbon-fiber on carbon-fiber action going on somewhere in Italy as you read this. Hit the jump for the full press blast.

  • Lamborghini Aventador carbon fiber monocoque

  • Lamborghini Aventador suspension

  • Lamborghini Aventador suspension

[Source: Lamborghini]
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Lamborghini makes no compromises in the engineering and construction of its new flagship's all-carbon fiber monocoque
• Monocoque forms a single shell in carbon fiber
• Built entirely in-house by Lamborghini with patented process

Sant'Agata Bolognese, February 11th, 2011 - Lamborghini's Geneva motor show launch of its Murciélago replacement promises an extraordinary new technology-driven super sports car. One significant feature will be the extensive use of carbon fiber-reinforced polymer (CFRP) technology throughout the car, and in particular, in the entirely carbon fiber composite monocoque.

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 loadbearing 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.

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 rigidity of 35,000 Newton meters per degree of twist. 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 developmening 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 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

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

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 millimeters, 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 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.

Carbon composite materials - A key technology for tomorrow's highperformance automotive engineering 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.

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    • 1 Second Ago
      • 4 Years Ago
      Thats incredibly impressive. When Lambo announced that they were putting a lot of money into carbon fiber research, I was interested to see what would become of it. Unless I am wrong, this will be the first super car to have a fully carbon fiber monocoque?
        • 4 Years Ago
        The pushrod and bellcrank allow for linear (or intentionally non-linear) wheel-to-spring motion ratios. If the spring and damper connect directly to the wheel, the motion ratio will be non-linear and the wheel rate will change as the suspension is compressed. By the geometry of the bellcrank, it looks like a non-linear motion ratio, but I'm sure there has been a large amount of research and simulation proving that to be the best choice for this car.
        • 4 Years Ago
        SCA are you serious? A push rod suspension lowers the mechanical advantage of a tire? I'd love to know where you learned this, maybe a link to enlighten me, because from what I've learned and seen what you just said is 180 degrees from the truth.
        • 4 Years Ago
        No.. I think McClaren F1... and the Mercedes/McClaren Vision SLR.... The inboard suspensiopn makes no sense though... unless there is an aero benefit, which is hwy F1 does it, it just adds mass and reduces mechanical advantage of the tire patch
      • 4 Years Ago
      Show the damn car already!?@!?@?!?@
      • 4 Years Ago
      I wonder how much of this is using the purported "forged composite technology" developed with Callaway Clubs...?


      Or as they put it:

      " Forged composite takes a different route by taking a toothpaste-like mixture of carbon fibers and epoxy and forming parts in a mold with over six tons of pressure. The result is cheaper carbon-fiber-reinforced materials that can be made in less time. And, since the arrangement of the fibers is random, the resulting material strength is omnidirectional; old-school carbon fiber is usually formed to be strong in just one direction."


        • 4 Years Ago
        I don't know, I don't think that provides any advantages. In that slurry-like state, the fibers are shredded. Might as well shred fiberglass instead. Carbon fiber's strength mostly comes from its weave. Its directional strength.
        • 4 Years Ago
        "Carbon fiber's strength mostly comes from its weave. Its directional strength."

        Umm... carbon fiber, pound-for-pound is stronger than ordinary fiberglass.

        And the issue IS directional strength. Structures within an automotive frame have stresses in more than one direction - and carbon-fiber is currently weak in the z-direction - that is, when the stress is perpendicular to the weave. That's the point behind z-pegging the weave, to reinforce it that way - but this also makes the weave as a whole weaker.

      • 4 Years Ago
      Guess how difficult it is to make the moulds and how much they are going to flog the buyers for the whole thing....
      • 4 Years Ago
      I wonder how many bodies they will be able to make per week? 3-10?
      • 4 Years Ago
      This thing probably costs more than what most of us drive haha.
      • 4 Years Ago
      324 pounds appears to be alot more than the 176 pounds of the Mclaren MP4-12C chassis? I guess I am not comparing like with like?
        • 4 Years Ago
        The McLaren Monocell (as they call it) doesn't include the roof and the pillars to support it as the Lambo monocoque does. My guess is that would account for most of the weight difference.
        • 4 Years Ago

        practically double the weight eh ?

        I question if it will be double as stiff or double the safety margins of the MP4-12C monocoque.

        And I wonder if the name Aventador will grow on me....like Murcielago did over time ?
      • 4 Years Ago
      Lamborghini is starting to get me excited with all this superlight weight bodies and high output engines and the stealth look. Sadly I can't say the same for that other itailian bunch who saw fit to release a station wagon instead of something equally light and equally aggressive.

      I'm a Ferrari fanboy, but Lamborghini you have my heart this valentines day.
      • 4 Years Ago
      Lamborghini has consistently made strong efforts to use CFRP in their vehicles, the latest being the new technology used and patented by the automaker to create this monocoque at a reasonable cost. Though making the body molds out of carbon fiber may not make a huge difference, the change is merely representative of the many possibilities for using plastics in automobiles, which in general comes with myriad benefits. For designers and engineers, this use of CFRP will allow them to develop faster and more efficient cars. For consumers, benefits include safety (in the case of a crash, this monocoque acts as a safety cage), more precise handling, and of course increased fuel efficiency due to the incredibly low weight that comes with using plastics in vehicles.

      Read more about plastics in cars on Facebook: http://www.facebook.com/plasticcar
      • 4 Years Ago
      I can't wait until this sort of technology has trickled down to the golfs.
        • 4 Years Ago
        Aluminum and magnesium technology is still in it's infancy among cheaper consumer vehicles. Honestly i don't think this will ever trickle down. They will probably find something else that is superior and more mass-producible. A monocoque in general wouldn't be good for pedestrian vehicles due to difficulty of repair. Besides, most consumers are beyond dumb, they are happy as long as their toaster is roughly as good as everyone else's toaster.
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