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Precision robotic weld technology: the NSX’s aluminum intensive space frame is constructed using advanced joining technologies.
The multi-material space frame is created with 100-percent robotic MIG welding, an automobile industry first. Eight weld robots apply 860 MIG welds to the space frame, ensuring highly precise and repeatable welds and a highly accurate body.
360-degree-rotating rotisserie-style body fixtures aid precision by turning the body during the process to provide optimal access for the robotic weld arms. In-line quality confirmation: highly skilled weld technicians both visually inspect and take precise measurements of each part and at every stage of the welding process to validate the quality, precision and dimensional accuracy of the space frame, which is critical for both the dynamic performance of the vehicle and precise fitment of its powertrain, suspension, body panels and other components in assembly. World-class Craftsmanship: hand craftsmanship complements the high-tech robotic processes throughout the assembly of the NSX:
Manufacturing technicians spend over 14 hours assembling the NSX powertrain, suspension, electronics, interior components and exterior body panels. Advanced visual operations standards aid technicians in ensuring that each process is performed to established requirements.
Critical bolts on the NSX are hand started by a PMC technician and tightened to precise tolerances using wirelessly enabled torque wrenches. This technology allows for the recording of torque settings for every bolt on every car, further ensuring quality in the assembly process. Unlike conventional cars with unibody construction where exterior panels are attached in welding, the NSX utilizes a space frame design, so that the exterior body panels are actually the last parts to be installed on the car. This allows for the exterior panels to be installed at a high level of precision, achieving superior fitment and maintaining world-class paint finish. All-glass quality confirmation center: A total quality approach to production is evident not only in the mindset of every PMC technician but also in the very design of the facility, which features a glass-enclosed quality confirmation center that is centrally located within the plant. This allows technicians from every department to monitor all aspects of a vehicle as it moves through the entire production process. Hand built engine: the NSX’s 3.5-liter twin-turbocharged V-6 engine with dry sump lubrication is hand assembled by master builders at the Anna Engine Plant. Each engine takes over six hours to assemble. Each and every component is hand assembled and each of 547 bolts is hand started and manually tightened to precise torque tolerances. Each NSX engine is machine balanced, bench tested and broken-in to the equivalent of 150 miles of service to ensure that every NSX engine is track-ready upon customer delivery. The engine build process was benchmarked against the company’s race engineering programs to ensure the highest possible quality and performance standards were achieved. First ever automotive application of Ablation casting: a first-ever application of new technology in the automotive industry, ablation casting, developed by Alotech, Ltd., is utilized for the creation of six nodes with the NSX space frame, serving as rigid suspension and powertrain mounting points and as critical elements of the vehicle’s crash structure. The ablation cast nodes are produced at the company’s Anna, Ohio engine plant, where its V-6 engine is also assembled. World-class exterior finish: with up to 11 coats of primer and paint, along with an extensive substrate preparation and polishing, the PMC achieves a high-quality paint finish unmatched in the class. Space frame with zirconium pre-treatment: the aluminum-intensive NSX space frame undergoes an etching process prior to application of corrosion-resistant primer using a zirconium-based material. While instrumental for world-class quality, the use of zirconium also reduces environmental waste in the painting process. Rotisserie-style sealer application: The use of two rotisseries in the body sealing application process – in which the space frame is loaded onto the fixture, elevated and rotated 360 degrees – provides for more precise application of sealer and improved ergonomics for technicians. The rotisserie is also employed in an industry first application in that it allows for one-sided attachment of the frame for more efficient loading and unloading and is a patent-pending design.