Audi Space Frame: from the first to the latest. The 5 Audi cars that revolutionised lightweight bodyshell construction

Audi is one of the manufacturers that revolutionised lightweight bodyshell construction in the automotive industry. Audi Space Frame, a technology that has revolutionised the way this component is manufactured, was introduced in 1994 with the first generation of the Audi A8.

The German brand has continued to develop this technology until reaching its latest stage, the multi-material bodyshell that features in the redesigned Audi A8. This type of construction uses a combination of aluminium, steel, magnesium and carbon-fibre-reinforced polymer, which reduces the overall weight of the vehicle and increases its torsional rigidity; a key factor in achieving good dynamic handling and good acoustics.

Throughout its history, Audi has presented several models that have influenced the way other manufacturers develop their bodyshells. These are the most notable models:

The Audi A8 (1994)

With the first generation of the Audi A8, the company became one of the first manufacturers to develop bodyshells using aluminium as the main material. The work began in 1982 and concluded with the presentation of the saloon at the 1993 Frankfurt Motor Show. The bodyshell of this model introduced for the first time the ASF (Audi Space Frame) designation. The Audi A8 caused a great sensation at its presentation with an unpainted bodyshell finished in polished bright aluminium (similar to silver).

The aluminium bodyshell of the Audi A8 weighed just 249 kilograms. Of its 334 individual components, aluminium was the dominant material, making up 71 per cent of the total bodyshell. The ASF aluminium technology of the first generation of the Audi A8 made the car 40 per cent lighter than a conventional steel design. This sparked a spiral of development among steel producers which has since led to new high-strength steels multiplying this value by five.

Audi TT (2006)

The second generation of the Audi TT was the first vehicle from the brand to incorporate the revolutionary multi-material ASF bodyshell. The front end, underbody and superstructure of the sports car were made of aluminium, a material accounting for up to 68 per cent of the vehicle’s total weight. Steel, on the other hand, was the main material used to build the rear section of the underbody and the rear end. To ensure good weight distribution, the doors and tailgate were also made of steel.

Compared with its predecessor (whose bodyshell was made 100% of steel), the new concept reduced weight by up to 90 kilos. It also allowed excellent weight distribution between both axles, with markedly greater torsional rigidity; two key aspects for achieving the dynamic behaviour characteristic of a sports car.

Audi R8 (2007)

For the R8, Audi transferred the ASF concept to a high-performance sports car for the first time. The total weight of the bodyshell was 206 kilograms and it was also made of multiple materials. Aluminium played a fundamental role in the bodyshell of the new sports car, accounting for around 70 per cent of the bodyshell’s total weight. In addition, the new Audi R8 also incorporated ultra-lightweight materials, especially in the Spyder version, where the rear side panels and the hood cover were made of carbon-fibre-reinforced polymer (CFRP); one of the materials featured in the new Audi A8.

Audi A8 (2010)

The third generation of the Audi A8 once again brought quite significant improvements. Its ASF bodyshell, built from 23 individual components, used thirteen different types of aluminium. The B-pillars were made of hot-stamped high-strength steel. The bodyshell of the saloon in its standard version weighed just 231 kg (an incredible figure for a model of these dimensions). With these higher-strength components, Audi increased the rigidity of this model by up to 25% compared with its predecessor, while also reducing its weight by 20 per cent.

Audi R8 (2015)

With the new R8, Audi once again reduced the weight of the ASF bodyshell, this time to 200 kilograms for the Coupé version. The decisive factor in this achievement was the combination of aluminium and CFRP (carbon-fibre-reinforced polymer).

The CFRP components form the backbone of the ASF. The outer body, including doors and bonnet, is made entirely of aluminium.