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Recently updated on May 2, 2023 at 07:07 p.m
monofuse layer
Lamborghini designed the Revuelto's body shell as a monofuse layer, a structural concept inspired by aviation. The entire monocoque is made of a variety of carbon fiber composites, the front end has a front structure made of forged composite. Lamborghini developed this composite material made of short carbon fibers and epoxy resin in 2008 and has been using it in structural components ever since.
The monofuselage structure increases the vehicle's torsional rigidity, reduces weight and improves driving dynamics. On top of that, the Revuelto is the first super sports car to offer a front end made entirely of carbon fiber. Even the cone-shaped impact absorbers in the front of the vehicle are made of forged composites. This design makes the component much lighter than a comparable metal structure and still ensures a significantly higher energy absorption - it is twice as high as the aluminum front end of the Aventador.
Overall, the monofuselage chassis of the Revuelto weighs 10 percent less than the body shell of the Aventador, and the front end even weighs 20 percent less than the comparable aluminum assembly of the predecessor. The torsional rigidity reaches a top value of around 40.000 newton meters per degree: an increase of 25 percent compared to the Aventador and a guarantee for enormous dynamic resilience.
The idea behind the development of the monofuse layer is based on the greatest possible integration of components. This approach is favored by the extensive use of forged composites technology and the development of the one-piece rocker ring. The arched, ring-shaped component made of carbon fiber reinforced plastic (CFRP) forms the supporting structure of the super sports car. It encloses and connects the forged composite elements such as the monocoque, the bulkhead and the A-pillars from below. Such use of carbon fiber components makes the Revuelto unique in the super sports car segment.
For the roof construction, Lamborghini retains the classic, efficient technology of autoclave composite manufacturing with carbon prepreg. The production in the autoclave meets the highest technical, aesthetic and qualitative requirements and also benefits from Lamborghini's highly specialized hand lamination process. This high level of craftsmanship is the result of years of quality-focused in-house production of composite components. In addition, this production method makes it possible to respond even more specifically to the individualization wishes of the customer.
The rear end consists of high-strength aluminum alloys, manufactured by Lamborghini using extrusion and hollow casting techniques. The engineers integrated the dome bearing mounts, the strut mounts, the rear wishbones and the suspension of the drive train directly in a hollow cast component. This significantly reduces weight, increases rigidity and minimizes the volume of the weld seams.
With the Revuelto, the AIM era of vehicle production with carbon fiber composites begins at Lamborghini: AIM stands for automation, integration and modularity. Automation refers to the introduction of automated and digitized processes in material processing. The traditional Lamborghini craftsmanship is still preserved, as in the field of composite materials.
With the integration, Lamborghini combines several technical functions in a single component, made possible by the advancement of the compression molding process. Engineers use preheated polymers to create a wide range of plastic parts of varying length, thickness and complexity. This ensures optimal integration of the components with maximum torsional rigidity. However, modularity also refers to making the technologies used modular and therefore more flexible and efficient in order to meet all product requirements and properties.
