Making cars is one of the epitomes of engineering applications. It starts with the designs best mirror dashcams where the laws of Physics, ergonomics, and style are being considered thoroughly, and then translates to the manufacturing of individual components via automated machinery and lastly, to the highly intricate and skill-demanding assembly line.
Imagine how high that level of engineering will be if you manufacture a luxury car such as a Bentley. The production process may be the same but the quality in their operations is just awesome. We will take a brief look at how the luxurious Bentley cars are made.
In the year 1919, brand Bentley was established. It has undergone a number of ownerships by premium brands like Rolls Royce, Volkswagen, and BMW all over its century-long run.
Bentley focuses on making luxury cars. The production is reliant heavily on the skill of individual artisans and therefore more attention and effort are being put forth in upholding the car’s quality. Modern Bentley cars are produced in their factory in Crewe, England.
The Bentley facility in Crewe, England accommodates around 3,700 employees, with all their mechanics, technicians, and operators holding certifications. 75 percent of the production is done by hand. For perspective on how much work is needed to produce a Bentley car, here are examples:
Bentley Continental GT 2-Door Coupe = 150 hours
Bentley Arnage 4-Door Sedan = 400 hours
Bentley Mulsanne = 400 hours
Modern engines like the W12 are molded from scratch. Super luxury cars built closely similar to a supercar takes more than 5,000 spot welds for the bodywork. The interior leather stitching is all done by hand.
The Crewe facility is one of the leading producers of W12 engines in the world. In just one engine, there are over 30 engineers working to complete the build in 12 hours.
The clay model of the Continental alone takes 6 weeks to create. The whole designing process, from inception to production takes 3 years at least.
The robots do the heavy lifting, while the human is responsible for welding the pieces together, inspect for imperfections, and make the necessary adjustments through a filing by hand. A part of the factory is storing the assembly-ready body panels that are formed off-site since the aluminum parts need more than 500 degrees Celsius of heat to be perfectly formed.
Have you seen the steering wheel of Mulsanne? It takes 5 man-hours to complete and requires 620 hand stitches from a thread stretching 10 feet.
The leather hides used to come from the bulls raised on Scandinavia and German farms. For a Mulsanne, it requires 14 leather hides while the Continental requires 9 hides and any leftover leather will be used on other parts of the car as the door handles, gear knobs, and dashboard. The needlework is no joke as it takes 150 hours to stitch the whole interior.
The interior wooden panels are from the same type of tree in order to have uniform grains, colors, textures, and other qualities. 25,000 square meters of the raw veneer is being checked by wood specialists and all stages of polishing of the wooden panels are done by hand.
Obviously, Bentley’s quality control is top-notch and they continue to improve further. The company builds models and conducts a series of extreme tests before proceeding to full-scale production. To ensure unbiased inspection, an independent external auditor will check 3 randomly selected cars every week.
The elegance and performance of a Bentley car are only as great as the ones making it. From the drawing board to the final checklist of quality control, everything is done with utmost thinking and skill. If you happen to own one, buying car accessories will be the least of your worries for you have an almost-perfect car already.