Production of the hypercar with Mercedes-AMG One Formula 1 technology begins | Manufacturing

Small series production of thehypercar equipped with the Mercedes-AMG One Formula 1 technology starts in Coventry in the UK.

alone 275 units will be built altogether.

The first vehicles will be delivered in the second quarter of 2022.

Formula 1 hybrid propulsion with a 1.6-litre V6 turbo engine and four electric motors is the work of engineers at Mercedes-AMG High Performance Powertrains in Brixworth (England).

The production of the complete Mercedes-AMG vehicle will be carried out by Multimatic in a dedicated small series production plant.

The production of the hypercar is handmade in 16 assembly stations and test benches.

Several working steps recall the production of watches High quality.

Some subsystems are first pre-assembled and tested for function, then disassembled again and finally installed in the vehicle. This is the case of the carbon fiber monocoque chassis with integrated roof as well as all the detachable body parts made of a light, stable and expensive material.

The entire exterior cladding is the first to be fully assembled.

All connections are thoroughly checked and, if necessary, adjusted according to size.

This is the only way to create perfectly homogeneous joints.

In the process, specialists must take into account the final lacquering, which adds its own thickness of material.

Given that the carbon’s wall thickness is only 1.2 millimeters in some places, this is an extremely sharp task.

Once everything fits together perfectly, the parts (including doors and hoods) are taken apart again and then hand painted for each individual vehicle.

The powertrain and body-in-white are assembled in the next step: The 1.6-litre V6 turbo engine, high-voltage battery and four electric machines have all been hot-tested beforehand on test rigs at Brixworth to verify that they are healthy and efficient. The process followed is exactly the same as for Mercedes Formula 1 powertrains.

Mercedes-AMG High Performance Powertrains supplies the corresponding units: the eTurbo hybrid combustion engine, the high-voltage battery of the plug-in hybrid, the front axle with the two electric machines and the power electronics including the inverter for each of the four electric motors.

In the workflow, 75% of the parts are already assembled prior to the installation of the high voltage components.

Overview of the production steps organized into 16 main stations:

• Stations 1 to 4: Assembly of mechanical parts and all low voltage components, and installation of essential powertrain components, including vehicle electricals.
• Stations 5 to 6: Assembly of the high voltage battery and high voltage connections, testing of the internal combustion engine and electric motors, and commissioning of the vehicle.
• Item 7: Indoor installation.
• Station 8: Start of installation of exterior body panel, doors and side panels. During this process, the pre-finished body panels (front fender, rear fender, side panels and doors) meet the main assembly line from the facility’s assembly sub-area.
• Station 9: Continuation of the exterior installation. Front and rear wing.
• Item 10 Final installation of the exterior bodywork.
• Item 11: Assembly of wheels and floor panels.
• Item 12: Wheel and headlight adjustment.
• Station 13: Chassis dynamometer for testing the vehicle in all driving modes.
• Station 14: Four post NVH tests (noise, vibrations, harshness), adjustment if necessary.
• Station 15: Monsoon rain test.
• Station 16: Lighting cabin with visual inspection of all surfaces and technical functioning tests of all components.

In all, more than 50 specialists work on every Mercedes-AMG One.

Each item is followed by thorough quality checks based on defined characteristics, resulting in complete documentation of the production process.

This meticulous manufacturing process is complemented by the latest Industry 4.0 production methods, which Mercedes-AMG also uses at the Affalterbach site for the production of AMG engines.

Components are pre-sorted into coordinated sets in material carriers and available at exactly the right time in the right place.

The final stage of the production of the hybrid hypercar is marked by a deployment on a test ground. Every Mercedes-AMG One undergoes final acceptance tests by a factory test driver.

After approval, the vehicle is fitted with appropriate transport protection and transported in a closed truck to the Mercedes-AMG headquarters in Affalterbach.

Both the technical briefing of the vehicle by the Mercedes-AMG One experts and the handover of the hypercar with Mercedes-AMG Formula 1 technology to its owner take place in Affalterbach.

“The Mercedes-AMG One is the most ambitious project we have ever undertaken, from development to production. It marks another high point in Mercedes-AMG’s successful strategic development towards an electrified future of Driving Performance. Exclusive small series production is an absolutely unique challenge. For the first time, the hypercar brings the current hybrid technology of Formula 1 almost identically from the circuit to the road and combines breathtaking performance with exemplary efficiency. This world premiere is becoming a reality thanks to the fantastic teamwork of Mercedes-AMG in Affalterbach, the Formula 1 experts at Mercedes-AMG High Performance Powertrains in Brixworth and our production partner Multimatic. The whole team is extremely proud to have started production of the first vehicles for customers.”says Philipp Schiemer, Chairman of the Board of Management of Mercedes-AMG.

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