Following analysis and development of new designs via 3D visualisation software, finite detail CAD analysis is performed. The resulting data feeds into the heavy processes including pressing, superforming (specialist hot forming), CNC machining and casting carried out by suppliers. Drawings are also created from the data to inform ‘the more artisanal hand crafted techniques used to create in-house components such as the wooden frame or leather interior trim,’ Wells explained.
Light machining forms part of some in-house processes. Aluminium panels and ash wood pieces, for example, are machine cut before being hand assembled or formed to create the car’s frame. As new materials and methods are adopted, labour skills are consequently updated. ‘Our craftspeople are always learning. The skills and techniques required to expertly handcraft a Morgan car are built up and passed down over generations. We have employees that have been with the company for more than 50 years as well as many apprentices,’ said Wells.
Using new materials
New materials and processes are fundamental to the Elemental Rp1, a road-legal track day car that went into production in 2016. The Rp1 goes from 0–60mph (0–97km/h) in 2.8 seconds, has F1 and Le Mans inspired aerodynamics, and an F1 driving position – it is the brainchild of ex-McLaren engineer John Begley, who founded the UK-based Elemental Motor Company in 2012 to bring his idea to market.
Some of the car’s carbon fibre components are manufactured using common methods for moulding and curing prepreg (pre-impregnated with activated resin) carbon fibre. But a variant of these processes – Elemental’s patent-pending CarbonAl technology – creates the Rp1’s 68kg tub. This has a carbon fibre dash panel, side pods and structural cross beams, bonded to front and rear bulkheads and a floor made from laser-cut aluminium sandwich panels. Peter Kent, Composites Director at Elemental said, ‘For the tub, we’ve used standard aerospace or motorsport materials with well-known properties, but we’ve come up with ways to keep the processing time down and create one-piece components that don’t require gluing.’