The McLaren MP4-12C carbon fibre “MonoCell”

Claudio Santoni

Function Group Manager - Body Structures

Troy – September 15th 2010 McLAREN MP4-12C – , – 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  CF MONOCELL  AIRBRAKE

 595BHP 3.8L TURBO  ACTIVE SUSPENSIONS 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 McLAREN First F1 car in history to race a carbon fibre 7 World Championship Titles in the upcoming 10 years Aerospace inspired Lightness and stiffness JOHN WATSON’S CRASH – Monza, 1981

6 McLAREN F1 – Woking, England – 1993

The “invention” of carbon road cars by McLAREN First Carbon Fibre road legal car in history In 1995 winner of 24hours of Le Mans – at his debut In 1998 fastest production car in the world at 240Mph Still the fastest naturally aspirated production car in the world McLaren Mercedes SLR – Woking, England – 2003

A selection of Carbon Fibre Technologies Adhesively bonded CF sections Best selling 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 PURE STRUCTURE • Designed around the occupants • Single piece moulding for excellent integrity • Every shape, every line has a reason • No “Cosmetic” function – pure structure MP4-12C CF MonoCell: DEFINING THE CONCEPT

STIFFNESS TO WEIGHT RATIO SURVIVAL CELL • Hollow construction • Designed to protect the occupants • Less than 80kg • Formula1 inspired • 4 years of virtual simulation and optimization MP4-12C MonoCell: MANUFACTURING PROCESS

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

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

3. FINISHING • Postcuring • 5 axis cnc machining • Finishing and QA MP4-12C MonoCell: SUPPLY CHAIN

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

MonoCell Manufacturing by CARBOTECH (Austria) CF MONOCELL CONCEPT By McLAREN AUTOMOTIVE

• Fibres by TORAY

• Epoxy resin by HUNTSMAN

• Tools and Machinery – various suppliers THANK YOU!