Carbon Fiber Manufacturing Process Revealed LP700-4

 

The Lamborghini development team carefully selected the following three main methods of manufacturing carbon fiber reinforcements in its technical tool portfolio: resin transfer molding (RTM); prepreg; and braiding.

 

 

Resin Transfer Molding (RTM): This process involves preforming carbon fiber mats and impregnating them with a precise amount of resin. The mats are then cured at high temperatures and the component is molded. Lamborghini achieved a major breakthrough in further perfecting this method.

 

Using the patented “RTM-Lambo” process, the final molded product is no longer a bulky, complex metal part, but a lightweight carbon fiber component, making the manufacturing process faster, more flexible and more efficient. Another advantage of the “RTM-Lambo” process is the low injection pressure, which eliminates the need for expensive equipment.

 

 

Prepreg: Carbon fiber mats treated in this way are usually called “prepregs”, which means that they are pre-injected with thermosetting liquid resin by the supplier and must be stored in a low-temperature environment. The carbon fiber mats are then laminated in a mold and heat-pressed in an autoclave. The manufacturing process of prepreg parts is very complex, but the surface finish is excellent (Class A finish), so they are the best choice for building exposed parts of the car.

 

 

Braiding: This carbon fiber weaving technology originates from the textile industry and is used to manufacture hollow parts for special purposes such as structural roof pillars and door sill panels. Braided parts are made by weaving the fibers in several layers in a diagonal direction. All parts are manufactured using RTM technology.

 

 

These technologies are used in a series of special operations to create the monocoque body of the new V12 super sports car. A major advance achieved by Lamborghini is the successful use of the assembled monocoque elements as molds for the next step of the process. This innovation greatly simplifies the manufacturing process compared to traditional methods.

 

 

Epoxy foam parts are also used in the monocoque. These parts are located in strategic locations to provide spacing between the layers of composite materials to increase the rigidity of the monocoque. In addition, the front and rear surfaces are laminated with aluminum panels to connect the front and rear subframe aluminum elements.