R8 production at Audi Böllinger Höfe near the Neckarsulm site

quattro GmbH manufactures the new R8 Spyder* in a purpose-built production facility, the “Audi Böllinger Höfe” in Heilbronn, close to Audi’s traditional Neckarsulm site. As many as 500 highly qualified employees build each car with painstaking craftsmanship at the 30,000 m2 (322,917.3 sq ft) facility. As was the case with the previous model, production is organized as a highly flexible factory. This offers virtually unlimited freedom to fulfill individual customer wishes.

In the body shop, the initial focus is on the aluminum parts of the Audi Space Frame (ASF). In a first step, specialists separately weld together the front body module, middle floor and rear body module – which are made of aluminum castings and extruded aluminum profiles – and then join the three modules to produce the underbody. In Superstructure and Finish, the body gets its side structure and add-on parts such as doors and the front hatch. Finally, it is painted in the color requested by the customer. The convertible top module – a closed unit – is bolted to the ASF at three points.

Only cold techniques are used to join aluminum to carbon fiber-reinforced polymer (CFRP). The ASF includes 215 semi-hollow punch rivets, 184 blind rivets, 244 metric and 286 self-tapping screws. An engineered adhesive (total length of the seams: 51 meters (167.3 ft)) and a special seal ensure that the metal alloy does not corrode in contact areas with the CFRP. The weld seams between the aluminum components have a total length of 84 meters (275.6 ft).

The finished body is transferred on a self-propelled assembly skid known as a driverless transport system (DTS) to the assembly shop, which is laid out as a U-shaped chain. There the employees work almost exclusively by hand in 16 assembly cycles of approx. 30 minutes each. In the interest of flexibility, there is no overhead conveyor. The cars move through the hall primarily on the DTS.

Audi makes no compromises when it comes to the quality of the R8 Spyder. Prior to delivery, every new high-performance sports car undergoes a stringent acceptance procedure. Its commissioning in the test center comprises six individual cycles, after which the car completes quality acceptance on the factory’s test track. After this, an approximately one-hour test drive that also includes freeway driving is conducted on public roads. Only then is the new Audi R8 Spyder released for delivery to the customer.

Available: market launch and prices
Presales of the new Audi R8 Spyder began in July 2016 at a starting price of 179,000 euros. Initial deliveries are scheduled by november.

The equipment, data and prices specified in this document refer to the model range offered in Germany. Subject to change without notice; errors and omissions excepted.