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The Aventador is the first test of this design direction. The National Geographic channel is located at the Lamborghini factory to witness the process of making the car's first parts.
This is Saint Acata, a beautiful neighborhood in the heart of Emilia Romanga county in Italy. But it is very special because it is the home of Lamborghini, one of the most famous supercar manufacturers in the world. The factory is located in the middle of a place called the valley of the automobile in the North of Italy.
Saint Acata is tied to Lamborghini's success, according to the head of communications: The whole world knows our car comes from Saint Acata. They visit our factory as a pilgrimage to a temple to visit the birthplace of the cars.
The factory has changed a lot over the years, but the purpose remains the same. Production of challenging cars is limited, most of the workers are locals they are from this region, not only this region but they are Emilia to be exact. We are in the Emilia Romaga district. This is my valley in Emilia county.
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Many of our employees not only live but were born here. They have been here for generations. Many workers in our factory, these people are the lifeblood of Lamborghini, more than 400 people work for one goal of producing high-class cars that appeal to the crowd. Over the past few decades, a new generation of innovative and high-tech vehicle specialists has emerged. Firms like Pagani and their determination to beat the most revered names in the supercar world.
Names like Lamborghini, giant Italian automakers will not give in without resistance. Attitude is shown right on the logo of the company Gaur. Inspired by the mighty bulls of Spain, one fought so bravely that it was awarded the trophy for courage in 1993. Its name is Aventador. Nearly 20 years later, its reputation is revived on Lamborghini's latest model. The fighting spirit of Aventador is what the development team has to convey.
In 2007 they faced the daunting task of building a supercar that would become the norm for all. The head of research and development realized that the only way to do that was to create something that never existed. We reshaped the car starting on a blank page. On it with each function define all the requirements to ensure the car is the best in the world. And redefine the entire structure of a super sports car.
A completely new design is very risky, having to convince the board of directors it is the right thing to do. Why is that really the hardest thing? because the project we proposed was different from the last one or anything that was ever produced. That means starting from zero with countless risks involved. But the board of directors decided it was worth the risk but in the end they agreed because that was Lamborghini's goal.
Creative and always have a breakthrough direction. Creativity is evident in every detail of the Aventador because Lamborghini understands that the battle for the top position cannot be won if half-done. The spirit of that fight is expressed above all in the focus on reducing vehicle weight and developing a completely new concept of the automobile.
Solid carbon fiber frame, this design is popular in racing cars, but the material is very expensive and labor-intensive to manufacture, causing supercar manufacturers that do not use them to combine carbon fiber with cheaper and heavier materials. like aluminum. That is until now the team has figured out a way to make racing technology become mass-market, but it needs a specialized factory for this.
So in 2009 they built a new large factory right at the company's headquarters to produce the Aventador's special carbon fiber bodywork. With a weight of only 1 kg, the Aventador is much lighter, which significantly improves the power-to-weight ratio. Lamborghini hopes this step will repel the risk of competition from a series of new competitors.
Lamborghini knows well what it's like to be a wild upstart challenging to overthrow the already established. Because that's how the company was born nearly 50 years ago. The limited challenger is the founder of the company.
Felicio Lamborghini made his fortune by producing tractors and using that money to satisfy his passion for sports cars. A legend about Lamborghini when he went to Ferrari to complain about one of their parts, his opinion was opposed when he made some requests and suggestions to make better cars so he said he wanted to be successful. Start your own company and build the best sports cars. He founded the Automobile Lamborghini company in 1.
A few years later he worked hard to achieve his goals, his cars were very welcome, but it was not until the iconic car's release in 1966 that Lamborghini made a real mark. The tractor manufacturer has successfully entered the world of supercars with a bold new company. Nearly 1 years later, even though it has joined the ranks of supercar manufacturers, the company still tries to maintain itself as a formidable and difficult opponent. Like their entry into what they believe will shape the future of lightweight carbon fiber supercar manufacturing.
The company has been using carbon fiber since the '80s when they built the prototype car using a composite material. The newly established composite department then came up with this idea, and the next generation employees continued to research and develop composite lightweight materials. And from the inventions born here or right next to it, the company can build a new carbon fiber factory.
The person who launched this mission in 2009 was Ranieti Niccoli, the executive producer. He had to plan from the very beginning. When we designed and built this factory we didn't follow any pattern, we were the only car company that built and used this technology so they had to take inspiration from other industries.
We looked at other industries like aviation and then emulated and modified their processes into Lamborghini's production system to build cars. As a result, the factory expanded to 500m2 called CFK. And this is the only factory to produce lightweight monocoque frames for the Aventador. Here 146 carbon experts work day and night to create 4 complete skeletons every day.
To achieve this goal the engineers have developed a special production system. All materials will be cut by automatic machines before being prepared. The material is placed into a mold and laminated during a vacuum process to force the layers into shape before being cured in a large pressure cooker called an autoclave.
While other parts of the frame continued to be manufactured, the master craftsmen cut additional layers of carbon with precision laser cutters. A special furnace is used to inject turpentine into the carbon system turning them from soft as fabric to solid. After completing this process we can recognize 1 main parts. The base is called the legs and the hood.
They are put into automatic factory. And drill holes for later assembly. Throughout the factory, computers control the machines and collaborate with experts, an integral part of Lamborghini's production process. The factory's top priority is Lamborghini's manufacturing process. So high skill level, skilled workers combined with technology and automatic lines. That is the big challenge in our factory.
Aeronautical engineering is ingrained in many stages of production, such as the harmonic hammer inspection. During quality inspection, the mechanic tapped a specially designed hammer on the chassis so that it hums and listens for flaws in the carbon fiber housing. After checking the parts are ready to be assembled when the legs and roof are joined together turning the frame into a single unit. The 1 parts of the frame must fit together so the mechanic uses a 2D laser machine robot to check the mounting holes are correct. When the dimensions were correct. The rest of the parts are attached to the frame and the bodywork is finished.
They are then taken to the light tunnel to check the surface to ensure they are not scratched before the Aventador bodywork is shipped. When the bodywork is ready to leave the carbon fiber factory, we can see for the first time the distinctive shape of the Aventador. The ultimate in design is the hallmark of Lamborghini. That tradition is maintained and developed here at Lamborghini's design center or Central Straight. The Aventador's demand for breakthrough does not stop at the creation of the car's shape is an important part of the company.
Lamborghini's design must always be revolutionary one must know when standing in front of a car that can only be Lamborghini even though they don't know the model yet. And that's the challenge for designers, who have to create both novelty and familiarity. The work of the design team and the team school was even more difficult in the early stages of the development of the Aventador when the board of directors forced them to compete with other manufacturers for the right to design the new model.
TThe most difficult advantage was the design process where we realized the risk of losing the whole project. This was the pivotal moment in the whole process when we realized we had to be more creative, more original, bolder, more unexpected and more formidable. Although it was difficult, the fighting spirit had a good effect on the whole group. And their proposal won. The result is a design that is steeped in the company's history. Our designs are rooted in the company's history, which manifests itself through a constant desire to innovate. Create a new product that embodies the foresight.
This is a piece of Lamborghini history. Some design features are considered key in the model of Lamborghini such as the famous scissor door opening, but in addition to full creative freedom, they have a sophisticated aesthetic eye but also understand the technical requirements of the Lamborghini. car. Because designs are chosen only when they help the car operate efficiently. Design must go hand in hand with function, so nothing is superfluous. Each air intake, each row of folding doors, all must be practical, not decorative. This was made even more difficult because they had to regulate emotions, a technical challenge for the design team was to provide the Aventador with enough air to cool the V1 engine.
In terms of design, we had to solve the problem that the car needed a large radiator on the side so there was a big vent hole from the front because that couldn't make the car into 1 parts like we used to. do. Now back to the actual design, this structure gives us the rare opportunity to design a car with just one stroke like this, just one stroke. This balance creates a car with styling that enhances its handling.
The car drew inspiration from many sources in one important tool for the team: the concept board. We take ideas from nature, sport, technology and life. Elements we can integrate. That goes beyond the idea giving us a wide range of design options. Details such as the start button, the display screen seem to originate from the cockpit of the jet. The airline industry no longer affects other details.
We think that aviation or fighter aircraft and even transport aircraft are the best expression of true beauty and top-notch design from an aesthetic as well as functional point of view. We know it is necessary to take inspiration from other fields and best and reference from nature. So we photographed the insects that inspired the shape of the hood, which is very dynamic and dynamic. As a result, the new model was immediately accepted as a different generation from previous models.
The task was completed and now when he saw the Aventador running on the road he felt its design even more clearly. I saw an Aventador next to the truck and I immediately called the exterior designer. Hey I see an Aventador in front of me that looks nice and elegant and the truck is so bulky.
I realized we were children when I saw our own achievements. The car was driven on the road, we love it more. Before the opinion is acknowledged there is still work to be done with the body of the Aventador.
After leaving the CFK factory it is taken to the most important stage: coating. In the paint shop, it is cared for the way other cars dream. Each of the 13 colors is hand sprayed on each body part. An expert groomed each of the 1 parts covering them with 27 liters of paint. The Aventador with its fine lines required more work than other Lamborghini models. Of course, each step is done manually.
Only humans are delicate and skillful enough to ensure that each surface is covered with the most accurate paint. In total, each Aventador takes 1 man-hours in the paint shop. The polishing alone took 200 days. Polished thoroughly with sand. The car is then polished several times with a special substance. Then the car was taken to check in the light tunnel. For 3 hours an inspector walked around the body of the car checking for color perfection. If there is a mistake, the color difference will be returned to be repainted. The areas that are not polished enough are also marked to be redone. These hundreds of meticulous hours come to an end when expert precision standards are met.
The car will be moved to the next stage: assembly. The Aventador assembly line is just meters from Lamborghini's first factory, built nearly half a century ago. At that time, the founder of Lamborghini was famous for his direct way of working. He is often at the factory to direct the production. He considers the skill of the mechanic to be the key to the product's success. It is still maintained at the factory today. Here, 50 people work at 11 workstations responsible for assembling Lamborghini's latest model.
The person who makes sure the line runs smoothly is the production manager. He considers his skilled workers as the core of the company. Here workers are trained a lot. We recruited them from the best engineering schools in the district around Lamborghini. And we train them for more than 2 years making them the best experts in engines and mechanics. Everything is still handcrafted as it was in 1963 when Felicio Lamborghini founded the company.
In a time when machines dominated production in all fields, loyalty to skilled manual labor was waning. But here they believe when it comes to reliability and accuracy humans still have an advantage over machines. That is more true in the engine assembly area because this is the heart of the assembled Aventador. Lamborghini's V12 engine.
At a time when many sports car manufacturers were afraid to use 12-cylinder engines, Lamborghini still used it. The V12 engine has been and will always power their flagship model. The V12 engine is part of what makes Lamborghini. With us everything is rooted in history starting with the 1-cylinder engine.
With a capacity of 6,5 liters and a capacity of 700 horsepower, the Aventador's V12 engine is very powerful, as well as everything else it has to change with time. Light weight is a necessity, although this engine is stronger, but it is lighter, only 1kg, which is due to the use of aluminum silicon alloy in details such as the engine block. The main function of the V235 engine is to create power for the Aventador, but when attached to the car's exhaust, it has another important role in creating the majestic Lamborghini music.
The V12 engine makes the car's musical sound that's how it appears to the public. It is its way of announcing its presence. To do this we spend a lot of time simulation. We simulated possible sounds in the lab first and then in the car itself. The sound of the 12-cylinder engine is full of resonance from a moderate growl when traveling slowly on the street to a powerful howl when accelerating gearshift.
While the V12 was being assembled, the body of the Aventador was taken to the assembly line ready to be assembled into a fully functional supercar. As the company's newest model yet to compete, the Aventador needed a corresponding production process. The market and competitors are the driving force in which we increase performance.
We must always be the best, the number 1 product in both performance and quality. Therefore, in order to become No. 1 and stay that way, we must always improve productivity, always improve the quality of the assembly line at all processes in the factory. The number of luxury cars the company produces is only a fraction of the number of large-scale car manufacturers mass-produced on the market. With about 1 Aventadors made in the first year. But that does not mean that the factory cannot operate with the same productivity standards as the big firms. That means workers only have 800 hour and 1 minutes to perform all the meticulous stages. If they take too long, the whole line will stop. Goals will not be achieved and costs will increase.
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That process begins at this first assembly site, where work is done on the rig and front shifter by lifting and rotating the bodywork for ease of operation by the mechanic. Before entering the most important stage in the production Aventador put the huge V12 engine into the chassis.
This is the most important part of the entire Aventador assembly line here we put the engine, the heart of the Aventador into the car we call it the marriage between the body and the engine. The departmental wedding is when the group's work over the past 4 years is brought together. Where design and manufacturing meet here as well as all other stages the specialist in any area will be fully responsible for that area. Each stage of assembly is marked to ensure it is done correctly.
