Launching a fascinating sports car such as the Audi TT in the highest quality calls for innovative production methods. For this purpose the Ingolstadt brand has invested approximately 295 million dollars in new production technology and equipment.

“Just like its predecessor, the new TT will be a joint production effort. Whereas the body will be built and painted at the main Audi plant in Ingolstadt, the final assembly of the TT Coupé, and later the TT Roadster, will take place at AUDI HUNGARIA MOTOR Kft. in Györ. This joint production method has proven to be a success since 1998. It therefore made sense to continue this successful partnership in the production of the successor model,” explains Dr. Jochem Heizmann, Board Member for Production at AUDI AG.

The TT body shop in Ingolstadt is completely new. The special body of the Audi TT Coupé is built here on an area of around 15,000 square metres. The body has an overall weight of 206 kilograms, 140 kilograms of which is aluminium and 66 kilograms steel.

Heizmann: “The lightweight design principle Audi Space Frame (ASF) has been further developed on the new TT and now also incorporates steel elements. If the body was built entirely of steel, it would be 48 percent heavier.” The individual components of the TT bodyshell, in total 277 – the majority of which are produced at its own press shop in Ingolstadt – are joined together in a “park” of 247 robots. The degree of automation is 95 percent.

Production will run at full capacity next year, according to Prellwitz. The TT Coupé will then be joined by production of the TT Roadster. “From that point onwards, we’ll be operating on the basis of a three-shift system,” explains Prellwitz. And this is by no means all: “Although the new TT contains more technical features than the predecessor model, we have already succeeded in cutting the previous production time from 15 hours down to the current ten.”

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