Technical details revealed for next-generation Acura NSX

(April 24, 2015) DETROIT — In advance of the market launch of the highly anticipated next generation Acura NSX, the engineers leading the supercar's development shared new technical details and design strategies with the automotive engineering community at the SAE Detroit Section dinner, held in conjunction with the SAE 2015 World Congress and Exhibition.

Additional information about the team's efforts to achieve a true "New Sports Experience" included details of the NSX's world's first body construction process that helped create a multi-material space frame resulting in class-leading body rigidity, the advanced total airflow management system and an update on NSX's power unit specifications.



Ted Klaus, chief engineer and global development leader of the new NSX, introduced key powertrain, body and dynamic performance engineers who s
hared new product and technical details in their related areas of the development. The unprecedented sharing of technical details prior to the car's market introduction reflects the desire of the NSX development team and the company to inspire the imagination of automotive and technology enthusiasts along with the next generation of engineers.

"Our goal is to create something altogether new and exciting, something that advances the concept of a next generation supercar in the spirit of the original NSX," said Klaus. "In order to provide NSX-level value, we needed to push ourselves to experiment with, refine and then realize many new technologies."

Significant technical revelations concerning the NSX included:

    • The NSX includes Acura's first use of a revolutionary multi-material space frame design that delivers class-leading body rigidity while remaining lightweight.

    • World's first automotive application of new ablation casting technology resulting in world-class body rigidity for ultimate handling and control.

    • World's first use of a three-dimensionally formed, ultra-high-strength steel A-pillar, supporting class-leading rigidity and crash performance while providing outstanding outward visibility.

    • The NSX achieves top-in-class aerodynamics targets without the use of active aerodynamic elements, while its three-motor Sport Hybrid power unit is cooled through 10 heat exchangers all thanks to a total airflow management strategy that maximizes the flow of air around and through NSX.

   •  Displacement of the NSX's all-new twin turbo V-6 engine was confirmed to be 3.5-liters.

    • The NSX will mark the introduction of the most capable and highest torque capacity Super Handling All-Wheel Drive system in Acura history.

    • The latest proprietary logic advances Acura's two decades-long pursuit of Super Handling that proactively responds to driver inputs, allowing the NSX to achieve a new level of line trace while at the same time intelligently supporting the driver in changing environments.

At the core of the NSX mission to deliver timeless sports car values is an aluminum-intensive, multi-material space frame. This innovative space frame represents a next-generation leap in body design with class-leading technology that is exclusive to Acura within the automotive market. Based on internal data, the all-new Acura NSX multi-material body is by far the most rigid in its competitive set.

While the all-aluminum monocoque body of the original NSX was ahead of its time, current aluminum and ultra-high-strength steel-intensive body architecture has been taken to the limit for supercar design.

"For this new NSX development, anything and everything that could offer incredible base rigidity and lightweight design was on the table," said Shawn Tarr, principal engineer and Acura NSX body development leader. "We considered all-aluminum unibody, carbon fiber monocoque and space frame designs and ultimately engineered a multi-material space frame because it offers the lowest weight and best rigidity, precision and hybrid powertrain packaging capability of any design."

A key advancement in casting technology allowed the NSX development team to realize a quantum leap in body design, for the first time being able to engineer a vehicle with castings in key locations for rigidity, that also support the ductility necessary for placement within crush zones.

The Acura NSX heralds the world's first application of ablation casting technology in the automotive industry. Ablation casting combines traditional casting methods with rapid cooling techniques to offer the design flexibility and rigidity of casting with the ductility and energy absorption characteristics of extruded material.

Traditional castings provide the ultimate rigidity in space frame and other body designs, but have traditionally suffered a major drawback: traditional castings are brittle. With the no-compromise performance goals of the NSX, a groundbreaking new casting method within the crush zones had to be used.

    • The ablation process allows the ultra-rigid castings to be located within the crush zones and to function as large aluminum nodes, or junction points. Aluminum extrusions are then inserted into sockets in the ablation cast nodes, which act as fixtures that hold the space frame in place during welding.

    • During the welding process, shorter stitch welds can be applied, enhancing the exceptional, repeatable precision of the NSX space frame construction by reducing heat deformation during the production process.

    • Ablation castings also enable traditional aluminum castings to be used at strategic locations in the space frame and as the primary mounting points for suspension and power unit components, in addition to being the reference and temporary attachment points during the highly accurate space frame construction process.

   •  Full space frame construction and vehicle assembly are conducted on-site at the new Performance Manufacturing Center (PMC) in Marysville, OH, providing a high level of quality control.