Giant 3D loom weaves parts for supercar

It's a sports car few people will be able to get their hands on. In production since last December, only 500 Lexus LFAs will be produced and they were already sold out in early June 2010 (see photo below). But it's not just its top speed of 325 kilometres per hour that's attracting buyers. The car is being used as a test bed for newly-designed parts made from carbon fibre and plastic. Compared to steel or aluminium, it makes the car stronger and lighter but producing these components is much more time-consuming: only one car is currently being assembled per day.

One of the key technologies being used is a high-tech circular loom, guided by lasers, that can weave 3D objects (see video above). The machine's futuristic design attracted lots of media attention two years ago, but the video was pulled for fear it would expose company secrets. Now Lexus is revealing how the loom is being used to create complex 3D parts with varying thicknesses and curved shapes. For example, it can create roof rails by weaving fibres around a core, two layers at time, until twelve layers later a hollow roof rail is produced. The piece can then be moulded and injected with resin to create the finished part. The machine was also used to create the car's chassis and front pillars as well as the steering wheel.

According to Lexus, 3D weaving technology reduces the volume of materials used by 50 per cent and increases their strength. The automated process should also make it easier to produce a large volume of parts in the future. They hope to use this machine, and other carbon fibre manufacturing technologies, to create more efficient cars.

If you enjoyed this video, you might also like to see a car designed to travel at 1600 kilometres per hour.