Italian automaker Pagani, maker of some of the world’s most exclusive sports cars, has installed the new Zünd G3 L-2500 carbon cutter as one of the few fully automated processes in the production of its limited-edition autos.
For years, Pagani, based in San Cesario sul Panaro, Italy, has used the Swiss-made Zünd PN L-2500 cutter, but upgraded when it moved into a new production facility. The primary goal was to gain more space and optimize individual production steps, according to company representative Luca Venturi. While the majority of parts that go into a Pagani are crafted by hand, cutting is one of the few phases of production that have undergone complete automation.
The cars’ chassis consist entirely of carbon-fiber parts; the Pagani Huayra BC weighs in slightly more than 2,600 pounds.
Each Pagani chassis is constructed from 240 carbon-based composite components. Depending on the required stiffness and strength, close to 10 different composites are used. One of these combines titanium and carbon fiber in a composite called Carbotanium, developed and patented by Pagani. It is roughly six times lighter than steel and provides the best strength-to-weight ratio in the automotive industry. Cutting titanium-reinforced carbon fiber is extremely challenging.
Pagani carbon fiber components are strictly made to order. The Zünd software automatically calculates the best placement of even the most complex cut contours and nests them together as tightly as possible. This automated process significantly reduces the time required for job preparation and setup, and maximizes material yield while minimizing cut waste. Malmusi said the process results in both labor savings and at least a 20 percent savings in material.