Lamborghini Sesto Elemento - a study in carbon fibre

Well, here it is. Over the past few days more and more leaks have sprung from the Lamborghini embargo pump, so to avoid any further loss of thunder the release has been brought forward to… now.

We’ll let you take a gander at the pictures while we go through the press release and decipher the Italian PR-speak. Enjoy.

An extreme lightweight sportscar in carbon fibre for sensational performance and handling

Lamborghini is redefining the future of the super sports car with a unique technology demonstrator. Boasting an extremely lightweight construction thanks to advanced carbon-fibre technology, the Lamborghini Sesto Elemento has an overall curb weight of just 999 kilograms (2,202 lb) – including V10 power unit and permanent all-wheel drive. This makes the Sesto Elemento a unique demonstration of the technological expertise of Automobili Lamborghini. Innovative carbon-fibre technologies are being used here for the first time in an automotive application. As a 100 percent subsidiary of AUDI AG, the Italian carmaker also benefits from the undisputed expertise of the German manufacturer when it comes to lightweight construction.

With its amazing output of 562 bhp, sensational power-to-weight ratio of only 1.75 kilograms per hp and 0 to 62 mph acceleration of only 2.5 seconds, the Sesto Elemento guarantees unparalleled driving fun. At the same time, fuel consumption also drops because of the extreme lightweight engineering applied throughout.

The name of this technology demonstrator is derived from the periodic table, where carbon is classified as the sixth element. Thus, the Sesto Elemento demonstrates the worldwide leading expertise of Lamborghini in carbon-fibre reinforced plastics (CFRP) technology. The super sports car brand from Sant’Agata Bolognese is the only vehicle manufacturer in the world to have mastered the complete CFRP process across a range of technologies, from 3D design through simulation, validation, production and testing – all in a state-of-the-art industrial process that stands for the very highest quality standards.

[blockquote type=”blockquote_quotes” align=”center”]The Lamborghini Sesto Elemento shows how the future of the super sports car can look – extreme lightweight engineering, combined with extreme performance results in extreme driving fun.[/blockquote]

Lamborghini drives the technology development in its two research centres the ACRC (Advanced Composite Research Center) and the ACSL (Advanced Composite Structures Laboratory) through collaborations with organizations such as Boeing, with the resulting technology secured under a host of patents.

“The Lamborghini Sesto Elemento shows how the future of the super sports car can look – extreme lightweight engineering, combined with extreme performance results in extreme driving fun. We put all of our technological competence into one stunning form to create the Sesto Elemento,” comments Stephan Winkelmann, President and CEO of Automobili Lamborghini. “It is our abilities in carbon-fiber technology that have facilitated such a forward-thinking concept, and we of course also benefit from the undisputed lightweight expertise of AUDI AG. Systematic lightweight engineering is crucial for future super sports cars: for the most dynamic performance, as well as for low emissions. We will apply this technological advantage right across our model range. Every future Lamborghini will be touched by the spirit of the Sesto Elemento.”

Systematic use of carbon fiber

The basis is an extremely solid, stiff, safe and lightweight carbon-fibre structure: the monocoque cell of the Sesto Elemento. The entire front frame, the exterior panels and crash boxes are also made from CFRP. The Sesto Elemento’s major suspension components and the rims are made from carbon fibre. The tailpipes are made from Pyrosic, which is an advanced glass-ceramic matrix composite, able to reach and stand very high temperatures up to 900° celsius. Even the propeller shaft is made of CFRP.

Amazing power-to-weight ratio

The Sesto Elemento demonstrates the outstanding expertise of Automobili Lamborghini in all areas of carbon-fibre technology. Carbon composite materials are a key technology for the automotive engineering of tomorrow, especially for high-performance sports cars. These materials made from carbon-fibre reinforced plastics combine the lowest weight with excellent characteristics – they are extremely stiff and highly precise. Lighter cars improve fuel consumption and CO2 emissions: above all, however, it improves the power-to-weight ratio – the crucial factor for a sports car – and thus the performance. A super sports car built using CFRP accelerates faster, has outstanding handling and better braking.

Perfect aerodynamics

The Sesto Elemento’s rear overhang is extremely short and, again, defined by optimum aerodynamics. The generously dimensioned spoiler is perfectly matched to the diffuser and a further air deflector in the centre, thus guaranteeing maximum down force for extreme cornering speeds and excellent high-speed directional stability. The Pyrosic tailpipes are directed
upwards through the engine cover panel, which also incorporates ten hexagonal openings and two air scoops behind the roof for delivering fresh air to the V10 power plant.

Interior – pared to the bone

The minimalist approach has also been applied to the interior, starting with the seats. Lamborghini has dispensed completely with the conventional seat frame. In fact, the whole internal structure is obtained and defined directly from the Forged Composite tub, that on one side plays a functional role and on the other side is the base for the optimally formed seat cushions, upholstered in hi-tech fabric, which are affixed directly to the carbon-fibre monocoque.

The correct ergonomics are provided by the steering wheel, which can be adjusted for height and reach, and by the pedals, which can be electrically adjusted longitudinally. Of course, the designers of Lamborghini Centro Stile also dispensed with interior trim in the classic sense. The dominant visual feature throughout is the functional CFRP material – on the floor and roof of the monocoque, on the doors and also on the cockpit and centre console.

Even the electronic control unit for the engine is mounted in plain sight – a very special kind of hi-tech aesthetic. The triangular cut-out is also evident as a design feature – wherever material can be removed in the interest of weight reduction.

The controls are presented in a highly concentrated format. The instruments provide information primarily on engine and road speed, as well as all parameters relating to engine condition. Only three piezoelectric buttons grace the centre console – one to start the engine, one to shift into reverse gear and another one for the lights.

Ambitious target reached with ease

The Sant’Agata Bolognese engineers had set themselves a target that was more than ambitious – despite the ten cylinders and 562 bhp, despite the exceptionally fast-shifting e.gear transmission and even despite the permanent all-wheel drive, the Sesto Elemento still had to stay below the 1,000 kilogram mark. And that target was achieved; at a kerb weight of 999 kilograms, each hp produced by the V10 power unit has to accelerate only 1.75 kilograms – a sensational figure.

This was made possible by the systematic and intelligent use of state-of-the-art carbon-fibre technologies. Lamborghini possesses extensive experience in the field of lightweight engineering, gathered over many years: something clearly demonstrated by the brand’s series production vehicles.

The current Gallardo LP 570-4 Superleggera has a dry weight of only 1,340 kilograms, marking a competitive best in this category of super sports cars. Compared with the already extremely lean Gallardo LP 560-4 Coupé, this represents a further reduction of 70 kilograms, resulting largely from the use of carbon fibre in the body-shell, interior and technical components.

Lamborghini engineers stuck firmly to this approach for the Sesto Elemento. Its structure consists almost entirely of carbon fibre and is built using the monocoque principle. Monocoque means that the vehicle’s load-bearing structure is manufactured as a single shell, with the physical properties of one component, and thus makes optimum use of the extreme stiffness offered by CFRP materials. Formula 1 racing cars have been built using CFRP monocoques for decades – and regularly provide clear evidence of their collision safety. The monocoque in the Sesto Elemento, however, is made using innovative Forged Composite technology – the first time this has been done in an automobile. The advantage of the Forged Composite is that the monocoque is obtained through a one-shot process.

Carbon fibre even in the suspension

The suspension and the area around the engine have also been optimized with lightweight engineering. Alongside aluminium components, there are also carbon-fibre control arms: innovative Forged Composite technology is also well-suited to this kind of high-load part. These components are around 30 percent lighter than comparable aluminium parts.

The propeller shaft is also made of CFRP by using Wrapping technology. This solution allowed the Lamborghini engineers to get rid of the central joint, bringing an important weight saving. The rims are also made from CFRP, while the brake discs are from carbon-ceramic composite material. A similar composite material is used for the tailpipes on the exhaust system – the compound of ceramic powder and synthetic resin makes this carbon material extremely heat resistant. A large number of screw fastenings feature a special titanium alloy and joining technology from the aviation sector.

What Next?

Clearly the Sesto Elemento is a concept study and was never intended to reach production, but it signals the direction Lamborghini will be taking in future, turning down the wick in their search for more power and instead achieving performance through lighter weight.

We can’t argue with that – it makes less of a difference for a low-volume supercar maker such as Lamborghini to pursue renewable energy sources, but less weight means less consumption and better dynamics. Maybe the future is bright after all.