Replacing steel and aluminium in the factory
on a quiet industrial estate in Bristol, in the west of Britain. The affectionate name has been given to what at first appears to be a giant loom from the Industrial Revolution. And in some ways it is. Bertha is an automated braiding machine. Like a horizontal maypole, ribbons of carbon fibre are drawn from 288 bobbins contained on a pair of huge rings, and passed over and under one another as they are wound tightly around a revolving mould.
On their own, carbon fibres are brittle and can break easily. But their strength comes in tension . So, the fibres need to be aligned in such a way to impart their strength by distributing loads throughout a structure. This is done by placing the fibres, tapes or mats onto a mould in the required orientation, creating what is known as a preform. It is a slow process often done by hand.
The company uses a specialist contractor to make MonoCells, although those for future car models will be produced at a new £50m McLaren Composites Technology Centre in Sheffield, Britain. The first of the new cells has just been delivered. Impressively, the large and complicated structures are produced within one go—although McLaren is keeping the details secret.
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