• Carbon fiber
• Composite materials
• Compression molding
• Mass analysis
• Statistics

The following thesis paper will focus on the production process of the newly introduced
carbon fiber monocoque (or “monofuselage”) chassis of the Lamborghini Revuelto,
which for the first time is produced using Carbon-SMC (Carbon Sheet Molding
Compound). Such an innovation created the necessity to set and validate new
technological constraints and process optimizations related to its application.
My experience began in March 2023 as an intern in Lamborghini’s CFK (Carbon
Faserverstärkte Kunststoffe, the German acronym describing carbon fiber) building in
the Sant’Agata Bolognese headquarters, where the Revuelto’s monocoque is built. The
Pre-Series Composites (PSC) department I was a part of has the task to follow its
industrialization and production steps from raw material to finished Body-in-White. The
Lamborghini Revuelto has, as of today, replaced the production of the previous flagship
model, the Aventador. An introduction to the company’s past and present is included in
the first chapter of this dissertation.
This paper will go through the short-fiber compression molding process in all of its
steps, explaining the production of the sub-components that make up the Revuelto’s
monocoque. In detail, the first part of the analysis will focus on the variability of the
raw material and the influence it has on the process and the components themselves,
while the second will build upon such analysis done within a longer timeframe to
optimize the process and propose a solution aimed at decreasing the production costs
through the application of mathematical and statistical methods, on a database of
recorded production variables (through the MES system). This work is a smaller part of
a joint effort between the PSC, Production and R&D departments to reduce rework times
on out-of-specification components.

The following thesis paper will focus on the production process of the newly introduced carbon fiber monocoque (or “monofuselage”) chassis of the Lamborghini Revuelto, which for the first time is produced using Carbon-SMC (Carbon Sheet Molding Compound). Such an innovation created the necessity to set and validate new technological constraints and process optimizations related to its application. My experience began in March 2023 as an intern in Lamborghini’s CFK (Carbon Faserverstärkte Kunststoffe, the German acronym describing carbon fiber) building in the Sant’Agata Bolognese headquarters, where the Revuelto’s monocoque is built. The Pre-Series Composites (PSC) department I was a part of has the task to follow its industrialization and production steps from raw material to finished Body-in-White. The Lamborghini Revuelto has, as of today, replaced the production of the previous flagship model, the Aventador. An introduction to the company’s past and present is included in the first chapter of this dissertation. This paper will go through the short-fiber compression molding process in all of its steps, explaining the production of the sub-components that make up the Revuelto’s monocoque. In detail, the first part of the analysis will focus on the variability of the raw material and the influence it has on the process and the components themselves, while the second will build upon such analysis done within a longer timeframe to optimize the process and propose a solution aimed at decreasing the production costs through the application of mathematical and statistical methods, on a database of recorded production variables (through the MES system). This work is a smaller part of a joint effort between the PSC, Production and R&D departments to reduce rework times on out-of-specification components.