Press Release
Page 1: Overview
Page 2: Mercedes & Mclaren
Page 3: History
Page 4: Specifications
Production of the Mercedes-Benz SLR McLaren and the limited SLR 722 Edition at the McLaren Technology Centre in Woking combines the best of both worlds: the advantages of the Mercedes-Benz production system coupled with McLaren's expertise in the construction of super sports cars. In addition, the SLR Experience Centre at the same location is the focal point for the SLR sales concept. Here customers can obtain the very best advice in highly exclusive surroundings and later take delivery of their SLR models in a spectacular hand-over ceremony.
Both variants – the Mercedes-Benz SLR McLaren and the SLR 722 Edition – embody the tradition and spellbinding allure of the Mercedes-Benz brand, while the Woking production site highlights the close links between the high-performance SLR sports cars and the world of Formula-1 racing. As well housing the SLR production facility, the McLaren Technology Centre is the hub of the McLaren Mercedes Formula-1 team's activities. Of the six "production fingers" that make up the complex, two are dedicated to SLR painting and final assembly, while the remaining four are principally used for development, testing and production of the McLaren Mercedes Formula-1 cars.
High-end components for unique high-performance sports cars
The SLR is constructed in Woking using high-end components manufactured by specialists from the partner companies DaimlerChrysler and McLaren. Mercedes AMG GmbH in Affalterbach produces the 5.5-litre V8 powerplant, while the British experts at McLaren Composites in Portsmouth on the south coast of England deliver the carbon-fibre composite bodyshell. At the heart of this co-ordinated production network is the McLaren Technology Centre where the Mercedes-Benz SLR McLaren is assembled.
The bodyshells are shipped to Woking from Portsmouth. Once they arrive at the paintshop – which is located opposite the final assembly hall - the carbon-fibre surface is painted by hand using a special process. Final assembly of the super-sporty Gran Turismo is largely performed by hand and takes place at nine stations along a line that is around 80 metres long. Each step is carried out in line with the standards and processes of the Mercedes-Benz production system, which was adapted to take into account the specific requirements of SLR production. Before moving on from one station to the next, the car has to pass through a quality gate so as to ensure consistently high standards. At the end of the assembly line, each vehicle must then pass a final examination on the chassis dynamometer before undergoing road tests to fine-tune the chassis. Only once the quality inspector and test driver have given the car the go-ahead can it handed over to the customer.
Automated production of CFRP components
At the McLaren Technology Centre, high-tech materials from the aviation sector and Formula 1 are being used for the first time in the series production of the body and chassis. The SLR's entire bodyshell, doors and bonnet are made from carbon-fibre composites (CFRP). Previously CFRP components were built by hand in a time-consuming process. In order to achieve a high degree of automation, the experts at the Mercedes-Benz Technology Centre in Sindelfingen, working together with DaimlerChrysler Research and McLaren, split the production process into two parts: preform production on the one hand and resin saturation with subsequent curing on the other. By drawing on the skills of the textiles industry, the materials specialists at DaimlerChrysler were able to introduce largely automated production of the preform, which also consists of carbon fibres. Furthermore, traditional production processes used in the textiles industry – such as stitching, knitting, weaving and braiding – were specifically adapted for the production of advanced CFRP materials.
By way of example, the longitudinal members of the front body structure consist of a central spine and the surrounding moulded part. The spine is made up of several layers of carbon fibre stitched together by machine. After the spine has been cut to shape, it is inserted into a braided polystyrene core. This core element is then clamped in a purpose-designed braiding machine that produces the longitudinal member from 25,000 ultra-fine carbon fibres that are unwound simultaneously from 48 reels. This process allows the fibre material to be braided around the core at a precisely defined angle to create the desired contour. Several layers are even overlapped in certain areas, depending on the thickness required.
In a further stage of production, a computer-controlled tufting machine – such as those used in the textiles industry – joins the spine inside the core to the braid of the longitudinal member. The braid core is removed and the preform of the longitudinal member is cut to size. Then resin injection takes place. Mercedes-Benz requires a cycle time of just twelve minutes to manufacture the complex fibre structure of the longitudinal members using a braiding machine, thus illustrating the potential production capacity that this innovative manufacturing technology offers for the future.
New method for manufacturing the rear shelf structure
The rear shelf structure of the Mercedes-Benz SLR McLaren provides a further example of the new production techniques for carbon-fibre processing. Although it has a complex shape with several apertures, it is automatically manufactured as a single part. To achieve this, DaimlerChrysler, McLaren and their collaborative partners adapted the SMC (Sheet Moulding Compound) method to create "Advanced SMC". Its advantage is that the carbon-fibre mats are no longer manufactured by hand but by machine. Here, a handling system arranges individual CFRP layers at pre-calculated angles and in pre-set positions which correspond to the principal shape of the component, thereby creating the blank. Under heat, this blank is then pressed, and in the process takes on the precisely calculated form of the rear shelf. No subsequent rework is therefore required. With the SLR, Mercedes-Benz is the world's first car manufacturer to use components produced using the "Advanced SMC" method.
In addition, the British company McLaren Composites produces over 50 carbon- and glass-fibre components for the high-performance sports car. The degree of integration achieved in the manufacture of the bodyshell is remarkable. By way of example, the entire floor assembly, including all supporting members and securing elements, is made from one piece. The cavities in the CFRP roof frame structure – also manufactured as a single piece – are automatically packed with foam before the resin is injected to create an extremely impact-resistant sandwich structure. High-strength bonding and riveting techniques ensure a reliable connection between the individual carbon components of the chassis and the bodyshell. The aluminium engine mounts are bolted to the CFRP bulkhead and also bonded in place, while the carbon structure includes integral metal mountings for the aluminium and steel rear axle.
SLR engine production: "One Man, One Engine"
The "One Man, One Engine" principle is applied to the production of the high-performance 5.5-litre powerplants, which is conducted in a purpose-designed hall at Mercedes-AMG's engine production facility in Affalterbach. The decision to bring AMG on board as the engine supplier for the SLR ultimately benefits the Mercedes-Benz SLR McLaren customers, thanks to the company's proven technology and its many years of experience in the construction of high-performance engines. The signature of the engineer responsible for building the engine, displayed on the AMG V8 model plate, documents the company's philosophy of exclusivity for the customer and guarantees the highest standards of quality and care.
SLR Experience Centre: the very best advice in the most exclusive of surroundings
Designed by the famous architect Sir Norman Foster, the McLaren Technology Centre not only offers the ideal conditions for producing the super sports car, it's also in keeping with the expectations of the SLR's exclusive clientele. Consequently, the focal point of the SLR sales concept is located here as well. As a core component of the complete "advice and experience" package, the SLR Experience Centre in Woking is designed to meet the specific needs of customers. In addition, these customers can choose to take delivery of their SLR here if they wish, in which case the car is handed over to its new owner in a spectacular show-style ceremony.
After arriving at the McLaren Technology Centre, guests are offered a wide-ranging programme of events, starting with a visit to the SLR production facility. Plus they get an exclusive insight into the Formula-1 development work that usually goes on behind closed doors. Comprehensive product advice and information presented in an appealing form is available in the showroom of the SLR Experience Centre. In addition, guests also have the opportunity to see just what the car is capable of at the nearby proving ground in Dunsfold, which is ideally equipped to test the high-performance machine to its limits away from the confines of public roads. Experienced racing drivers are on hand to provide any assistance that may be needed here. If requested they will sit in either the driver or passenger seat and explain the features of the SLR in detail. The exclusive SLR advice and experience package is rounded off by a special programme of events in London.
