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Ferrari Forever

Foundry-Planet tours the Ferrari foundry and production in Maranello.

Lesedauer: min | Bildquelle: Ferrari S.p.A.
By: International Editor, Sarah Praetorius

‘There are two religions in Italy. There’s the Catholic Church and there’s Ferrari.’  

We arrive a few days before Lewis Hamilton will burn rubber on the '70s tracks in Maranello. Naturally, the Scuderia Ferrari hopes he will be their next legend. The Ferrari complex is truly like nothing we have ever experienced.  

As we stroll through the Ferrari Citadel, we are met with consistent elements of surprise and design genius.   

Two robots, lovingly named Romeo and Juliet, exchange rings as part of the composition of a V8 engine. A jungle blooms amidst silver industrials for the workers' well-being. The factory shines both glossy and futuristic, as cars rotate over our heads.  

‘Here the soul enters the body,’ someone tells us as we watch a vehicle’s engine carefully being raised into its housing.  

There is a level of perfection that seems to border on divinity. It feels a little like standing in God’s workshop as he is putting a human together.   

Indeed, Enzo Ferrari himself wasn’t shy to put human elements into his cars. The founder, who saw the car and driver as one organism, often had heady conversations with his Formula 1 drivers. Michael Schumacher’s and Niki Lauda’s ‘feeling’ of the car was then integrated into the design. Their essences now live on in the cars.  

‘You can feel the spirit of Enzo Ferrari,’ someone tells us as employees bustle around coffee like a F1 pitstop.  

Certainly, there is something that can be felt. When an insatiable strive for perfection and passion, meets artistic vision, it curiously creates something immaterial, invisible yet tangible and alive. It’s like a soul is created that runs like lifeblood through Ferrari. Perhaps, this is the myth of Ferrari.  

Now, this myth enters a new epoch. We met with three Ferrari chiefs, Paolo Molinari (head of powertrain manufacturing), Franco Pinna (head of technology and innovation), and Giacomo Lorenzin (head of foundry and machining technologies), who told us all about the next chapters of the legend.


So, what does the future hold for Ferrari? Particularly, regarding the EU’s combustion engine ban in 2035.  

‘The classic Ferrari customer can expect that he can buy a Ferrari ICE until 2035,’ the team shares.   

Like Ferrari declared on its investor day, it will continue its use of hybrids, ICEs, and full electrics as long as possible. ‘We do not believe in one single way to get to the target,’ the team says. The idea is to leave no stone unturned.  

‘We will continue on this path of not choosing one technology over the other for our customers. We want them to be able to do so. That doesn't exclude any technology at the moment, even the ones that are more future-looking.’  

A new electric vehicle will soon join the Ferrari family and launch at the end of this year. However, the electric will not replace its other models. Instead, Ferrari sees EVs as one more slice added to its cake.  

‘In the end, the important thing is not the power. The important thing is that Ferrari is still Ferrari for our customers. If we manage to build a car that is allegedly, but also in reality a Ferrari, then the problem does not exist.’  

‘We like to say different Ferrari for different Ferraristi at different moments,’ the team explains.  

However, this is more than just marketing.  

‘If you think of our range at the moment, it’s so diverse. It goes from the Roma to the SF90, two completely different worlds, two different types of people, probably also at different moments.’  

Some customers prefer to be traditional; some prefer to be greener, others wish to be more performant.  

‘But luxury is just that, luxury is about being different. Luxury is about one's feeling of uniqueness.’  

The challenge is serving these needs from the same foundry, the team laughs.

In terms of its foundry, it seems Ferrari has not caught the gigacasting fever yet. While the firm is still evaluating the technology's possibilities, Pinna says it currently doesn’t see any immediate use for its products. 

The foundry has however innovated its power. ‘We are using 100% green energy,’ says Molinari. This was an important milestone towards neutrality that the firm had last September. In addition, Ferrari plans to eventually use 100% recycled alloys to reduce their carbon footprint. Ferrari has also adopted an ESG attitude that encourages blue-collar and white-collar staff to find sustainable solutions. 

 ‘We're using human resources and human capital to try and get the finish line as soon as possible.’ 

Looking to the future, Ferrari innovation wants to anticipate needs. 

Similar to the advent of the iPhone, Ferrari doesn’t want to follow the demands of the crowd but invent new demands for the crowd to chase. Their cars are already very different from what they were 10 years ago. The range now includes a plug-in hybrid, a four-door, and a soft top - technologies and cars that a decade ago were probably unthinkable to Ferrari.  

‘Now, they're here and they're true Ferraris, we love them. The important thing is to stay true to the DNA - who we are, to continue being recognized as a legend and winner in sports and racing,' he says. 

After all, ‘Ferrari is forever.’ 


The Ferrari Foundry in Maranello  

The Ferrari foundry in Maranello is an integral part of the production process for Ferrari engines. It plays a key role in the manufacturing of aluminum components used in Ferrari's high-performance engines. Through state-of-the-art technologies and precise manufacturing methods, the foundry ensures the highest quality standards for Ferrari’s legendary engines.  

Location and Function  

  • Location: Maranello, Italy, in the heart of the Ferrari headquarters  

  • Function: Production of essential aluminum components such as cylinder blocks, cylinder heads, and other parts for the famous V12, V8, and V6 engines  

Capacity and Resources  

  • Facility Size: 9,500 m³  

  • Workforce: 128 skilled workers, including 9 dedicated to quality control and special projects  

  • Shift Operations: 3 shifts per day for continuous production 5 days a week  

  • Production Volume: 3,500 tons of aluminum per year  

  • Material Quality: 100% premium-grade aluminum  

  • Casting Equipment:  

  • 6 fully automated casting cells  

  • Sand casting carousel for efficient serial production  

  • More than 50 different core types for various engine designs  

Casting Processes 

The Ferrari foundry utilizes advanced casting technologies to meet the high standards of precision and material quality. The main processes include:  

  • Sand Casting  

  • Gravity Die Casting

  • Ferrari is evaluating Low-Pressure Die Casting for future products

  • Cold-box Conventional Core Shooting

  • 3D Printing for Sand Cores for prototypes

Special Casting Processes for Exclusive Projects  

  • Hand-mold Foundry: For prototypes and special custom-made components  

  • Ferrari Classico: Production of parts for historic Ferrari vehicles and restoration projects  

  • Custom Castings for Formula 1: High-performance components for motorsports applications  

Post-Processing and Quality Assurance  

To ensure maximum precision and quality, all components undergo additional processing steps after casting:  

Heat Treatment  

  • Optimization of mechanical properties such as strength and durability  

CNC Machining  

  • High-precision milling and machining processes to meet tight tolerances  

Quality Control  

  • Application of advanced inspection methods:  

  • X-ray inspection to detect casting defects  

  • Ultrasonic testing for material analysis  

  • 3D metrology to ensure exact specifications  

Technological Innovation  

Ferrari continuously invests in research and development to enhance the efficiency and precision of its foundry.   

Significance for Ferrari  

The foundry plays a crucial role in ensuring the performance and uniqueness of Ferrari engines. By producing key components in-house, Ferrari maintains full control over quality and design. This secures the company’s technological advantage in the high-performance and motorsport segments.  


 

Firmeninfo

Ferrari S.p.A.

Via Abetone Inferiore n. 4,
41053 Maranello

Telefon: +39 0536 949111

[1305]
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