The legendary car manufacturer FERRARI: between tradition and transformation

We arrive at the Ferrari production facilities a week before Formula 1 star Lewis Hamilton is due to make his mark here. It quickly becomes clear that in Italy there are two major institutions: the Catholic Church and Ferrari.

The Ferrari complex is an impressive synthesis of industrial precision and aesthetic excellence. During our tour of the production facilities, we repeatedly come across innovative design elements and unexpected technical details.

Two industrial robots, affectionately known as “Romeo and Juliet”, assemble high-precision components of a V8 engine. Green spaces between the production lines are designed to optimise the working environment. The entire production hall exudes a futuristic atmosphere, whilst autonomously guided vehicles operate along the production lines.

“This is where technology and emotion come together,” remarks an employee as we observe the assembly processes. 

Ferrari pursues a holistic development approach that goes far beyond mere mechanics. Enzo Ferrari viewed the interplay between driver and vehicle as a single entity. The experiences and feedback of racing drivers such as Michael Schumacher and Niki Lauda were incorporated directly into the design – their influence can still be felt today. 

“You can sense Enzo Ferrari’s vision,” explains an engineer, whilst the factory staff work on the cars with great precision and efficiency – almost like a Formula 1 pit stop.

Future Focus and Technology

Ferrari is on the cusp of a new era. In conversation with three senior managers – Paolo Molinari (Head of Powertrain Manufacturing), Franco Pinna (Head of Technology and Innovation) and Giacomo Lorenzin (Head of Foundry and Machinery Technology) – we gain insights into the future strategy. 

How will Ferrari position itself in the context of electrification and the planned EU ban on internal combustion engines from 2035?

“Ferrari will continue to offer vehicles with internal combustion engines until 2035,” the team confirms. “As communicated at our Investor Day, we are committed to a combination of hybrid, internal combustion and electric powertrains. There is no single path to the future, but rather various technologies that will coexist.”

A fully electric Ferrari is already in development and is set to be unveiled at the end of this year. However, the introduction of an electric vehicle will not spell the end of conventional models. Rather, Ferrari views electrification as an additional pillar within its model range. 

“Ultimately, it’s not the type of powertrain that counts, but the fact that every Ferrari remains a true Ferrari. If we manage to preserve the brand’s DNA, there will be no break with tradition. We like to say: ‘Different Ferraris for different Ferraristi on different occasions’.” 

This approach is deeply rooted in the company’s philosophy. The model range extends from the sporty and elegant Roma to the high-performance SF90 – different concepts for different target groups.

“Luxury means individuality and differentiation,” explains the team. “Our challenge is to meet diverse requirements with the same precision.”

Production strategy and sustainability

Whilst many manufacturers are turning to gigacasting technologies, Ferrari remains cautious. “We are analysing the potential, but currently see no immediate need for our production methods,” explains Pinna. 

Instead, Ferrari has made significant investments in sustainable energy sources. “Our production runs on 100 per cent renewable energy,” emphasises Molinari. With this, Ferrari has reached an important milestone on the path to carbon neutrality, which the company officially declared in September. Furthermore, Ferrari plans to use 100 per cent recycled alloys in future to reduce its carbon footprint.

Sustainability is also promoted internally. Ferrari relies specifically on the innovative strength of its employees to develop sustainable solutions. 

A trailblazer for new developments

Ferrari does not see itself as merely reacting to market trends, but as a trailblazer for new developments.

“We do not want to fulfil existing desires, but to create new needs – much as happened with the invention of the smartphone. Our aim is to develop technology that sets new standards.”

The evolution of the model range shows that Ferrari is constantly evolving: today, the product range includes plug-in hybrids, four-door models and soft-top convertibles – concepts that would have seemed unthinkable just ten years ago. 

“But the key point is that every Ferrari retains its origins and identity. We will continue to be perceived as an iconic brand and a leading force in motorsport,” says the team.

Because one thing is certain: Ferrari remains Ferrari – forever. 

A profile: The Ferrari foundry in Maranello

The Ferrari foundry in Maranello is an integral part of the production process for Ferrari engines. It plays a key role in the manufacture of the aluminium components used in Ferrari’s high-performance engines. Using state-of-the-art technologies and precise manufacturing methods, the foundry ensures the highest quality standards for Ferrari’s legendary engines.

Location and function

• Location: Maranello, Italy, right at the heart of Ferrari’s headquarters

• Function: Production of essential aluminium components such as cylinder blocks, cylinder heads and other parts for the production of the famous V12, V8 and V6 engines

Capacity and resources

• Area: 9,500 m³

• Staff: 128 skilled workers, including 9 specialising in quality control and bespoke manufacturing

• Shift work: 3 shifts per day for continuous production 5 days a week

• Production volume: 3,500 tonnes of aluminium per year

• Material quality: 100% high-quality premium aluminium

• Casting facilities: 

• 6 fully automated casting cells

• Sand casting carousel for efficient series production

• More than 50 different core variants for various engines

Casting processes offered

The Ferrari foundry employs state-of-the-art casting techniques, to meet the high standards of precision and material quality. The most important processes include: 

• Sand casting
• Gravity die casting
• Ferrari is evaluating low-pressure casting for future products
• Cold-box core shooting process
• 3D printing of sand cores for prototypes
• Special casting processes for exclusive projects
• Hand-moulded casting: For prototypes and bespoke items
• Ferrari Classico: Manufacture of components for historic Ferrari vehicles and restoration projects
• Bespoke components for Formula 1: high-performance components for motorsport

Post-processing and quality assurance

To ensure the highest precision and quality, the components undergo further processing steps after casting: 

Heat treatment

• Optimisation of mechanical properties such as strength and durability

CNC machining

• High-precision milling and machining processes to ensure tight tolerances

Quality control

• Use of advanced testing methods: 

• X-ray inspection to detect casting defects

• Ultrasonic testing for material analysis

• 3D measurement technology to ensure compliance with exact specifications

Technological innovation

Ferrari continuously invests in research and development to enhance the efficiency and precision of its foundry.  

Significance for Ferrari

The foundry makes a significant contribution to the performance and uniqueness of Ferrari engines. The ability to produce components in-house gives Ferrari full control over quality and design. This secures the company a technological edge in the high-performance segment and in motorsport.