Crafting the World’s Most Expensive Production Car
Following our previous exploration into designing a Bugatti Chiron, the automaker has now revealed the process behind building the world’s fastest (electronically capped at 261 mph) and most expensive car ($2.6 million, not including options).
A total of 1,800 components make up a new Chiron, assembled in Bugatti’s Molsheim, France factory, which notably lacks conveyor belts or robots. Instead, every part of the Chiron, except for the engine—a 1,500-hp quad-turbo W-16 engine pre-assembled by Volkswagen in Salzgitter, Germany—is handcrafted across 12 workstations, a process that can take up to nine months.
The Details and Structural Integrity
This meticulous craftsmanship entails applying up to eight layers of paint to the body shell, with each coat hand-sanded and polished before the next is added. Building the rear end accommodates the powerful engine, requiring a complete overhaul of the dynamometer first utilized for the Veyron, which couldn’t handle the Chiron’s immense power. Boasting the title of the most powerful rolling dynamometer globally, it supports the Chiron during acceleration tests, reaching speeds of up to 124 mph while Bugatti contributes surplus power generated back into the local grid.
Fitting exterior carbon panels can require up to three days. Due to their thinness, technicians must pre-install them on specific frames that replicate the actual car to check for irregularities. Following the assembly of these panels, a 30-minute monsoon test assesses the car for leaks. The comprehensive shake-down procedure then includes testing top speed runs on an airfield, reaching up to 155 mph, before the vehicle returns to Molsheim for final preparations and inspection, leading to a highly celebrated delivery.
The detailed information released by Bugatti clarifies this intricate process.
FEBRUARY 07, 2017, MOLSHEIM
Inside the Molsheim Dream Factory—A Visit to the Bugatti Chiron Production Facility
Fuel efficiency: 35.2 liters/100 km in urban areas; 15.2 liters in extra urban areas; 22.5 combined; CO2 emissions: 516 g/km; efficiency category: G
Currently, 12 Bugatti Chiron super sports cars are in production at the brand’s “Atelier” facility in Molsheim. The first deliveries are set for the first quarter of 2017, with a goal of assembling up to 70 vehicles this year. The gap between starting production and delivering a Chiron averages six months. A skilled team of 20 employees hand-assembling more than 1,800 individual parts allows for the creation of the world’s most powerful, fastest, and luxurious production super sports car, ensuring rigorous quality control throughout the process.
The Molsheim facility, a picturesque site in Alsace since Bugatti’s establishment in 1909, seen as the home where automotive dreams are realized through the Chiron. The initial step involves customers configuring their vehicles with a Bugatti designer, emphasizing the bespoke nature of each car. Customers personalize their Chiron through a detailed selection process, choosing from 23 exterior colors and a wide array of interior materials and finishes, offering thousands of options for customization.
Production planning proceeds only after the customer has approved the configuration. This initiates a complex and highly-timed manufacturing process, taking approximately nine months. As customer customization diverges, the timeframe required for assembly may vary greatly.
Once a production slot is secured, the necessary parts are ordered. Bugatti’s suppliers, primarily situated throughout Europe, begin preparing components for timely delivery to Molsheim.
Approximately one month before assembly begins, the chassis is first fitted with the bodyshell and monocoque, ensuring compatibility. Each part is identified with its own kit number before moving to the paint area. The painting process spans three weeks, requiring multiple layers of application. Particularly in instances of visible carbon fiber, Bugatti sets the standard for production quality and color variety with as many as six layers needed for finishing. Depending on the ordered finish—uni, metallic, or pearlescent—top coats may require up to eight layers.
With the assembly process underway, Christophe Piochon, a Bugatti Board member overseeing production and logistics, oversees operations to guarantee smooth workflow and the absence of complications, noting, “our facility can’t be compared with larger assembly plants.” He adds that “just-in-time” coordination is uniquely tailored to Bugatti’s operations.
The Molsheim Atelier spans over 1,000 square meters, established in 2005. Oval in shape, the facility mirrors the Bugatti logo. It was designed by renowned architect Professor Gunter Henn. Modifications were made to accommodate the complexity of Chiron production, including pre-assembly of external components for initial inspections. Additionally, a new dynamometer was developed capable of managing the Chiron’s immense power output. Significant changes were applied to the Atelier’s flooring, which now includes conductive epoxy to eliminate static charges while creating an ambiance akin to a fashion runway. “We build supercars here, but how we do it—crafting individually tailored products—truly sets us apart. This is ‘Haute Couture de l’Automobile,’” remarks Piochon.
In contrast to conventional automotive assembly lines, Bugatti relies on manual craftsmanship. Working at 12 distinct stations, employees conduct operations as if they were part of a Formula One team. The assembly begins with the powertrain, pre-assembled at Volkswagen’s Salzgitter facility and subsequently tested for eight hours.
At the second station, the powertrain is affixed to the chassis, maintaining a weight equal to that of the previous Veyron despite significantly increased power output. Two building platforms accommodate multiple workers throughout the assembly process, focusing on ensuring all employees are proficient in completing the full chasis installation.
As the build progresses, crucial cooling systems are integrated, equipped with three water pumps and extensively designed piping to maintain optimal engine temperature. The only electronics utilized during assembly involve an advanced nutrunner system that tracks torque applied to the numerous bolts used, required for over 1,800 joints.
The marriage of the monocoque and rear end is a significant assembly milestone, secured with 14 lightweight titanium bolts chosen for their weight efficiency. Finally, the chassis proceeds to the filling unit for operational fluids, followed by the first ignition of the 16-cylinder engine, marking an exhilarating point in production.
Following initial tests on the newly designated rolling dynamometer—capable of managing the Chiron’s immense power—the extensive testing for durability and performance commences. The dynamometer, modified significantly for the Chiron, allows for electrical generation while simulating high-speed performance conditions safely.
After completing all dynamometer assessments, the vehicle’s body is installed, with notable attention to detail guiding this intricate process of fitting carbon-fiber components. The following water test, exposing the Chiron to simulated heavy rainfall for leak detection, precedes the interior fitting stage where luxurious trims are installed.
Upon completion of the interior, the Chiron is prepared for final inspection drives, including a thorough cleaning process after protective coverings are removed. Test drives utilize alternative wheels to preserve the original set, culminating in rigorous evaluations across the scenic Vosges area and high-speed testing on airport runways.
Once the test drives conclude successfully, the Chiron undergoes meticulous cosmetic preparation, including a comprehensive inspection and polishing under controlled light to guarantee perfection in finish quality. The final approval process involves numerous heads of departments ensuring the vehicle meets Bugatti’s rigorous standards before scheduling delivery to the eager customers.
Most customers will have toured the Molsheim facility frequently by this point, engaged in the configuration process and finalizing specifics of their personalized Chiron. The entire production process takes about two months, culminating in the creation of the world’s most esteemed super sports car. A dedicated team, including quality assurance specialists, will subsequently provide ongoing support to ensure the vehicle remains in pristine condition for its owner, solidifying its place as the crown jewel in any collection.
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