09/07/2010 — Automobili Lamborghini S.p.A. announces a new Advanced Composites Research Center (ACRC) at its headquarters in Sant’Agata Bolognese. The center carries out research on innovative 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 constitutes a breakthrough into the next generation of carbon-fiber components.

Carbon-fiber technology is crucial to the future
“The consistent development of carbon-fiber 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 fiber, 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 for super sports cars
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 sportscar is improving its power-to-weight ratio and thus its performance. A super sportscar built using composite materials in carbon fiber has improved acceleration and braking as well as superior handling.

Gallardo LP 570-4 Superleggera: lightweight engineering champion thanks to carbon fiber
The current Lamborghini Gallardo LP 570-4 Superleggera offers a perfect example: compared with the already extremely lean Gallardo LP 560-4, its weight has been trimmed by a further 70 kilograms. One major contributing factor is use of exterior and interior components made from carbon fiber. The super sportscar from Sant’Agata Bolognese weighs in at no more than 1340 kilograms – the new benchmark for the exclusive market segment occupied by Lamborghini.

Over thirty years of experience at Lamborghini
Lamborghini has many years’ experience in composite elements. The first carbon-fiber 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 fiber, with 93 kilograms of structural carbon-fiber 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 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.

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-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.

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-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.

Exclusive Program Lets Customers Help Create Their Own Corvette

DETROIT – For enthusiasts who want to be personally involved in creating their Corvette, Chevrolet’s new Corvette Engine Build Experience allows them to literally build the engine for their new car.

In what is believed to be the world’s most hands-on super car program, customers who order a 2011 Corvette Z06 or ZR1 can choose an option to help assemble their cars’ LS7 or LS9 engines at General Motors’ Performance Build Center (PBC) in Wixom, Mich.

“Corvette owners are some of the most passionate – and most involved – enthusiasts in the industry,” said Jim Campbell, U.S. vice president, Chevrolet marketing. “The Corvette Engine Build Experience offers customers an unprecedented opportunity to participate, hands on, in creating the car.”

In addition to building their own engines, Corvette buyers can attend driving school in Arizona or Nevada, take delivery of their vehicles at the National Corvette Museum or watch their vehicles being built at the Corvette assembly plant in Bowling Green, Ky.

“In a way, this is a dream program for a Corvette customer. I would have jumped at the chance to build the 427 in my ‘67 ‘Vette, and that didn’t have half of what goes into one of these modern precision engines,” said Tom Stephens, GM vice chairman, Global Product Operations. “Today’s LS7 and LS9 Corvette engines are pinnacle achievements in engineering, and to personally involve our customers in their final creation shows the depth of Chevrolet’s commitment to make lasting connections with the customer.”

The Engine Build Experience is an option with a suggested retail price of $5,800. When a customer selects the PBC option for a 2011 Corvette Z06 or ZR1 and the dealer submits the order to Chevrolet, a special concierge contacts the customer to verify participation and help coordinate arrangements. While travel arrangements to and from Metro Detroit are the customer’s responsibility, the Chevrolet concierge helps schedule the engine build; coordinates the customer’s activities at the Performance Build Center; assists with booking local lodging and meals, and arranges local transportation.

At the PBC, the customer doesn’t merely view the engine’s assembly; he or she builds it under the supervision of and support from skilled technicians. When the engine is assembled, a personalized nameplate is added to the engine next to the builder’s name. It is then sent to the Corvette assembly plant for installation in the customer’s car.

The Corvette Engine Build Experience is possible because of the hand-assembly processes used at the 100,000-square-foot PBC. Technicians hand-build the Corvette Z06’s LS7 7.0L engine, the Corvette ZR1’s 6.2L supercharged LS9 engine and a variation of the Corvette Grand Sport’s LS3 6.2L engine. The PBC incorporates the best practices of low-volume niche manufacturers and the established quality and manufacturing standards at GM to ensure the highest-quality specialized engines.

Like all engines assembled at the PBC, Engine Build Experience engines are covered by Chevrolet’s five year / 100,000-mile transferable powertrain warranty.

The Engine Build experience is the latest program Chevrolet offers for Corvette owners. Other programs include:
Corvette plant tour, where customers can follow their vehicle down the Bowling Green assembly line
Corvette Museum delivery, where customers take delivery of their new Corvette at the National Corvette Museum in Bowling Green
Corvette ZR1 Driving School, which offers complimentary attendance at either Bob Bondurant’s Corvette Driving School in Arizona, or Ron Fellows’ Corvette Performance Driving School near Las Vegas.

“Simply put, no other sports car manufacturer can match the level of personal customer involvement that Corvette offers,” Campbell said. “The Corvette Engine Build Experience takes this personal involvement to an unprecedented level.”