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I had a personal 1:2 tour around the lotus/caterham f1 facility when they were local to me, got to see what went into making all of there carbon wings/diffusers body sections nose cones etc.

It took weeks of hand laying precision cut sections of carbon to a scripted assembly guide to create one product, and they usually had to make numberous copies because they had to be tested and destroyed to make sure they were safe etc. The surprising thing was how thick the main body was, was about 2-3" thick solid CF with some alloy inserts for mounting etc. All of which had to go into an enclave and be vacuumed and heated. Was a crazy amount of work for something that would be out of date in weeks.

The labour itself wasnt overly expensive as they were just production workers following a guide that had been set by designers etc but its the sheer hours that went into it due to the copies that had to be made would have made it costly.

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