Materials World
July 2017, pages 34-37
Modern materials play a major role in the evolution of extreme high performance sports cars. Sharon Ann Holgate speaks to bespoke motor manufacturers about the materials and processes used to create their latest models.
The current generation of bespoke supercars and sports cars relies on carbon fibre composites, specialist alloys and advanced design and manufacturing techniques for their extraordinary shapes, speed and handling characteristics. Pushing the boundaries of materials use and processing is enabling small, craft-based companies to create cars with truly unique qualities.
‘The key to sports car performance is weight. You can add massive power to nearly any car, but lightness means faster acceleration, shorter braking distances, less inertia when you enter corners and much greater control. To be as light as possible, you need advanced materials technology,’ said Steven Wade, copywriter for Swedish bespoke supercar manufacturer Koenigsegg Automotive, which was founded by Christian von Keonigsegg in 1994 to create the ‘perfect supercar’.
Koenigsegg’s latest model, the Regera – a hybrid combining electric motors with a V8 internal combustion engine that can reach 300km/h (186mph) from a standstill in 10 seconds – has a chassis tub made from carbon fibre with an aluminium honeycomb sandwich construction that weighs just 72kg. Carbon fibre is also used for the exterior and interior panels, steering wheel, seats and several engine components including the cam covers, airbox and intake plenum.
The Regera’s six-spoked ‘Tresex’ hollow carbon fibre wheels contain 750 individual pieces of carbon fibre and takes an artisan 10 days to make. They weigh around 40% less than Koenigsegg’s lightweight alloy wheels. Wade explained that ‘lighter wheels mean faster acceleration off the line as well as minimal rolling inertia, which is critical both when braking and cornering at speed.