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Step inside the secret lab creating Maserati's future

MODENA, Italy – Driving Maserati's raucous GranTurismo MC and the effortlessly quick Levante SQ4 back to back feels like traveling through time. Horsepower doesn't go out of style, but a user interface quickly does, and the GranTurismo looks like it's from another era in that respect. Designers, engineers, and executives are busily orchestrating a transformation that will ensure the 105-year old firm's next leap forward is even more dramatic. Autoblog went behind the scenes in Maserati's Innovation Lab – which has never been opened to outsiders before – to find out how the looming metamorphosis will shape Fiat-Chrysler Automobiles' (FCA) flagship brand. Maserati is on the brink of a ground-up redesign that will take it into new segments of the market, and diversify its powertrain palette. We heard the term electrification used on many occasions during our visit, though company officials resorted to automotive omerta when we asked for additional details. An earlier product plan reveals every upcoming addition to its line-up will be available with an electric powertrain, and there will be quite a few cars to electrify. Historically a small, almost niche automaker, Maserati is on track to release five new models between 2020 and 2023, including a second SUV positioned below the aforementioned Levante, plus replacements for most of its current cars. Technology is playing a significant role in Maserati's renaissance. The company's four-year-old Innovation Lab is home to simulators capable of reproducing six months' worth of wear and tear in two weeks. Engineers can dial in a variety of situations, locations, and road conditions, ranging from a winding country road in France to a busy highway in southern California. They can digitally insert potholes, add rain or fog at the push of a button and remove either just as quickly, and put virtual prototypes on a long list of race tracks around the world, including the Nurburgring. Digital wind tunnels help the team test future cars well before they're built. This approach saves time and money, explained Luca Dusini, the man responsible for Maserati's vehicle dynamics testing and simulation. Making every dollar and each minute count is key to pulling off such an ambitious overhaul. 90% of development work is carried out on the various simulators, according to Dusini. This is significant, because Maserati is developing most of the technology it will pack into its future models from scratch.

Watch Maserati prep this Quattroporte for Geneva by hammering on its sheetmetal

There are untold amounts of primping and set up that goes on in the days leading up to an international auto show. Of course, there are exhibits to erect, lights to hang and scripts to rehearse. There are also cars to prep. Usually the latter involves little more than removing finger prints and dusting, but in the case of Maserati the day before the Geneva Motor Show press days, the process apparently includes banging on the sheetmetal of one of your prized showcars like a crazed woodpecker.
We're not sure what caused a surface irregularity in the door skin of this 2014 Quattroporte - perhaps shipping damage - but it was interesting (and mildly painful) to watch, and hear, a show prepper attempt to repair this six-figure sedan with what looks like a jeweler's hammer, high-intensity light and soft cloth.
That'll buff right out.

Bizarre Levante mule proves SUV will ride on Maserati platform

When Chrysler was developing the current Jeep Cherokee, matte black, lifted Alfa Romeo Giuliettas weren't an unusual site around the company's Auburn Hills, MI headquarters. That's because the Jeep rides on a modified version of the Alfa's platform.
Judging by these images, Maserati is following a similar path for the upcoming Levante. The presence of the modified and lifted Ghibli basically confirms that the company will look in-house for the new CUV's platform rather than outsource it to Jeep (otherwise, we'd be seeing modified Grand Cherokees running about).
The mule's Ghibli body has been fitted with a number of tweaks. Most notable are the higher roof and stretched wheel arches, which we're guessing are an attempt at increasing the sedan's center of gravity and width, respectively, in a bid to match the eventual production model.