Q&A: How Essential Are Composites to Lamborghini’s Future?

Paolo Feraboli, assistant professor of aircraft materials and structures at the University of Washington (UW), is the driving force behind a new laboratory by Lamborghini

Paolo Feraboli is assistant professor of aircraft materials and structures at the University of Washington (UW) and the driving force behind a new UW laboratory funded by Italian automaker Lamborghini. A former Lamborghini employee himself, Feraboli discusses why the famous automotive company is moving forward with composites as its key technology for the future.

What testing will be done at the UW facility?

We have a full-scale crash facility so we can test front end and side impact. We also can do pressure testing of small component sections. Those things are Lamborghini-related, but we built it in mind as a service to other companies as well, such as Lamborghini’s partners.

Why do composites appeal to Lamborghini?

Lamborghini’s strategy is to increase the power train ratio for future generations of cars by reducing weight rather than increasing power. They see more benefit in weight reduction than increased power or unlimited flooring at the current rate. In order to reduce weight, Lamborghini chose to use carbon composites as the key technology, at least for the next few years.

How does Lamborghini use composites?

The Murcielago, a high-end 12-cylinder engine model, uses extensive carbon composites. The entire body is carbon fiber as well as the floor, transmission tunnel, wheel housing and bumper section of the chassis; making composites 31 percent of the total structural weight.

How can composites usage expand in high end cars?

We’re moving away from standard prepreg and looking into infusion and compression molding and modified version of RTM. Most of the stuff we’ve worked on in the past 10 years is focused on production for the Murcielago. We produce about 500 of those per year, but our goal is to push the technology to a level where we can increase that output to 2,000 to 3,000 cars per year. That would bring composites to another level of usage, but the only way to achieve that is to move away from prepreg.

How will moving away from prepreg help?

Traditionally, carbon-intensive cars have been built at the rate of two-a-day or possibly two-a-week for niche products. The idea is to transition to a level which is still considered a supercar level (not mass produced), but it’s still a decent-sized production. Later on we’d want to move to a 15,000 a year level, which is more in the line of Corvettes. If the cost of the process keeps going down without the prepreg, there will be a chance to shift down to press mold.

What can manufacturers do to address these issues?

The biggest thing is work with out of autoclave properties. The future lies there, so putting their foot in that method is the biggest step for future success. Figuring out ways to use liquid infusion and RTM is the biggest challenge. The goal is to improve rate and time.

What composite concerns do you hear most often?

People wonder if composites can handle a crash, especially at high speeds. People typically believe that composites are brittle and therefore wouldn’t hold up in crash situations. Yet, the exact opposite is true! Composites have much more energy per unit weight than metal. Because composites shatter, it can absorb a lot more impact.

Another misunderstanding people have is that composites are problematic because they’re not isotropic and therefore properties vary according to their location. In reality, that’s not a very big issue. The big issue is that composites aren’t homogenous. The fact that composites aren’t a monolithic material (it’s made of two different bases) throws people off and is what creates the most potential for problems. You can’t predict where a crack would grow, because it changes its orientation based on where it hits a fiber and switches planes.

Are there any other projects of note?

I can’t comment, but we’re always working on new technology.

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For more information on Paolo Feraboli amd the new Lamborghini funded laberatory, attend COMPOSITES 2010′s General Session, where Feraboli will participate on the emerging market panel.