The McLaren MP4-12C carbon fibre “ · PDF fileThe McLaren MP4-12C carbon fibre...

The McLaren MP4-12C carbon fibre “MonoCell”

Claudio Santoni

Function Group Manager - Body Structures

Troy – September 15th 2010

McLAREN MP4-12C – Woking, England– 2010

Launched on March 2010, the MP4-12C is McLaren’s first in a range of innovative high performance sports cars

CARBON FIBRE AT THE HEART OF THE 12C

ACTIVE SUSPENSIONS

AIRBRAKE

595BHP 3.8L TURBO

CF MONOCELL

HISTORY OF CARBON FIBRE CARS

In the past 30 years, McLaren has not built a car without a carbon fibre chassis

McLAREN MP4/1 – Woking, England – 1981

The “invention” of carbon fibre F1 racing cars by McLARENFirst F1 car in history to race a carbon fibre monocoque7 World Championship Titles in the upcoming 10 yearsAerospace inspired Lightness and stiffness

6

JOHN WATSON’S CRASH – Monza, 1981

McLAREN F1 – Woking, England – 1993

The “invention” of carbon road cars by McLARENFirst Carbon Fibre road legal car in historyIn 1995 winner of 24hours of Le Mans – at his debutIn 1998 fastest production car in the world at 240MphStill the fastest naturally aspirated production car in the world

McLaren Mercedes SLR – Woking, England – 2003

A selection of Carbon Fibre TechnologiesAdhesively bonded CF sectionsBest selling supercar ever (2,114 between 2003 and 2009)Up to 4 complete body per day

MP4-12C CF MonoCell – Woking, England – 2010

DEFINING THE CONCEPT

BODY STRUCTURE OVERVIEW

MANUFACTURING TECHNOLOGY

MP4-12C MonoCell: DEFINING THE CONCEPT

FORM FOLLOWS FUNCTION• Designed around the occupants • Every shape, every line has a reason

PURE STRUCTURE• Single piece moulding for excellent integrity• No “Cosmetic” function – pure structure

MP4-12C CF MonoCell: DEFINING THE CONCEPT

SURVIVAL CELL• Designed to protect the occupants• Formula1 inspired

STIFFNESS TO WEIGHT RATIO• Hollow construction• Less than 80kg• 4 years of virtual simulation and optimization

MP4-12C MonoCell: MANUFACTURING PROCESS

1. CARBON FIBRE LAYUP• Multiaxial NCF and Stitched UD• Potential for automation

3. FINISHING • Postcuring• 5 axis cnc machining

• Finishing and QA

2. MONOCOQUE RTM MOULDING• Fully automated RTM work cell – 4 hours ftf• Single piece Monocoque moulding •Excellent Dimensional accuracy and consistency• Scalability

MP4-12C MonoCell: SUPPLY CHAIN

MonoCell Manufacturing by CARBOTECH (Austria)

• Fibres by TORAY

• Epoxy resin by HUNTSMAN

• Tools and Machinery – various suppliers

12C Assembly at the newMcLAREN PRODUCTION CENTRE (MPC) in Woking, UK

CF MONOCELL CONCEPTBy

McLAREN AUTOMOTIVE

THANK YOU!