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Lamborghini opens center for carbon fiber research

Lamborghini is advancing its supercar technology through an investment in a new Advanced Composites Research Center (ACRC) at its headquarters in Sant’Agata Bolognese, Italy.

The center carries out research on design and production methods for carbon-fiber elements. Both the ACRC and an all-new, highly efficient production process for extremely complex carbon-fiber structures were developed at the same time. The process is secured through an array of patents and is claimed to constitute a breakthrough into the next generation of carbon-fiber components.

“The consistent development of carbon-fiber technology is a key element of our strategy,” said 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 fiber, even at a 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.”

The 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 optimized 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-fiber structures.

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-fiber parts under high pressure and temperatures. Efforts focus, however, on “out of autoclave” technologies such as Resin Transfer Molding (RTM), whereby carbon-fiber structures are compressed under high pressure; or vacuum RTM, whereby resin is forced into carbon-fiber using negative pressure.

Lamborghini ACRD’s specialists have already achieved a definitive breakthrough with the invention of a new 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-fiber 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.

The Center is not Lamborghini's only resource for carbon-fiber research as, 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.
 

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