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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!