Formula One regulations have demanded that the racing cars be constructed from carbon-fibre-reinforced plastics (CFRP) for some years now. The first chassis made exclusively of carbon fiber was used by McLaren in 1981, and it was not long before all other Formula 1 vehicles on the racetrack had the same sort of chassis fitted. The cars comprise a monocoque that offers the driver a high-strength survival space, as well as crash structures to dissipate the impact energy extremely effectively and uniformly. It is primarily as a result of this that the risk of injury in high-speed accidents in this Blue Riband motorsport event has dropped significantly.
Lamborghini Aventador Rolling Chassis. Carbon Fiber Monocoque.
The MonoCell is produced in one piece through the Resin Transfer Moulding (RTM) process. The result is a lightweight, hollow, yet very strong and predictable structure. The production process begins by loading dry carbon fibre into a complex 35-ton steel tool before it is pressed together, heated and then injected with epoxy resin. Using a steel tool is new to the manufacturing process: historically, carbon chassis’ have been formed in ‘soft’ tooling of composite materials, which adds production costs and time. The subsequent post-curing process hardens the resin, and the MonoCell then enters a booth where key surfaces are machined with great precision in preparation for vehicle assembly. The process between forming and curing produces the MonoCell as a hollow structure, and is the key to the chassis’ combination of strength and light weight. Once complete, the MonoCell is placed into a unique McLaren-designed test rig and subjected to high stresses, in order to prove that each part is capable of meeting exacting performance standards.
compartment.
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