ALFA ROMEO USE RENSHAPE MODELLING BOARDS FOR FIRST SUV CONCEPT VEHICLE
30 June 2003 - Huntsman Advanced Materials

Known as the Alfa Kamal project, the concept vehicle had to be completed in time for display at the Geneva Motor Show in March 2003. Here it was well received by the world’s automotive industry, as Alfa Romeo’s first move into the rapidly growing Sports Utility Vehicle market.

The project began with Alfa Romeo’s design team providing sketches and digital data for the vehicle to modelmakers at Stola S.p.A.’s production facility in Turin.

Initially a 1:4 scale model was produced and used by the Alfa design team for evaluation and assessment. A full scale model was then machined from RenShape BM 5185 modelling boards.

Note: the succession of the stages is as follows:
1. The Alfa Romeo designers have made a 1:4 scale model for their initial
assessment of the project.
2. They converted the sketches into digital data.
3. Then they mastered the surface study on a full scale model. (This wasn’t made
with RenShape boards).
4. The semi-final mathematical data were then supplied to Stola who machined the
full scale model out of RenShape BM 5185, under the supervision of the Alfa
Romeo designers.

Chosen for its easy machinability and excellent surface finish quality, RenShape BM
5185 is a lightweight material with a low coefficient of thermal expansion. It offers the right combination of physical properties and workability to make it ideal for the rapid production of high quality models in the automotive industry.

“During this development stage, many alterations had to be made as our ideas were still evolving and adjusting while the car was being shaped and built,” explained Mario Favilla, designer at Alfa Romeo. “So the material we used needed to be easy and quick to machine, as design changes were immediately converted into digital data and entered into the computer guiding the milling machine. This meant there was no significant interruption in the working process.

“It was this combination of precision and speed of production by using RenShape
boards that enabled us to complete the Alfa Kamal project in only 20 days from when the first drawing was sketched.”

On completion the machined model was polished to a flawless finish which was then
primed and painted. A special automotive metallic paint was used to give the high
glossy finish required for a fully functional prototype vehicle that was to be on public display.

The RenShape BM 5185 board model was then mounted on a metal chassis and tinted glass windows were added to complete the concept vehicle.

“We use RenShape modelling boards for many of our projects, including the famous Stola S81 sports car,” said Alfredo Stola. “We find this material extremely reliable. Its combination of strength and flexibility makes it particularly suitable for meeting the demands our of world-leading automotive customers.”

The Alfa Romeo SUV is expected to go into production in 2005 and will be targeted at the rapidly growing active leisure market, for drivers who need space to carry sports equipment combined with performance and the ability to go off-road.

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