Cupra harnessing 3D printing to boost speed, safety and efficiency

Cupra harnessing 3D printing to boost speed, safety and efficiency

27.03.2020: New Leon Competición model to use 3D printed door mirrors, air intakes and cooling intakes CUPRA using state-of-the-art multi-jet fusion technology for the race vehicle 3D printed parts tested in wind tunnel face gusts of


    New Leon Competición model to use 3D printed door mirrors, air intakes and cooling intakes

    CUPRA using state-of-the-art multi-jet fusion technology for the race vehicle

    3D printed parts tested in wind tunnel face gusts of more than 180mph

    Parts help reduce fuel consumption while also increasing stability, speed and safety

    The Leon Competicion will be the first touring car to be available for online ordering

    It has a 2.0-litre turbocharged petrol engine with 335bhp, allowing for a 162mph top speed



A team of innovative engineers is transforming the way vehicles are developed by printing car parts.




CUPRA is using state-of-the-art multi-jet fusion technology to fashion parts in a fast and efficient way.



For its new Leon Competición racing car, engineers at CUPRA have 3D printed the model’s door mirrors, air intakes and cooling intakes.



The technique enables the manufacturer to reduce the vehicle’s fuel consumption while also increasing stability, speed and safety – vital in both motorsport and road car applications.



The process of printing a mirror can take around 20 hours, but CUPRA can print six at a time, giving the team the ability to create different designs simultaneously. This means CUPRA can quickly test the varying prototypes in a wind tunnel to find out which is best for aerodynamics.



When taken to this controlled environment, the printed parts are fitted to the car and face winds of more than 180mph while sensors study the impact on individual surfaces. The car's resistance data is displayed on screen where engineers and designers compare the results for the different printed parts. 



As the smallest margins can make the difference in motorsport, it is crucial the 3D printed parts play their part in reducing fuel consumption while also increasing stability, speed and safety.



Xavi Serra, head of technical development at CUPRA Racing, said: “For the new CUPRA Leon Competición we modelled the steering wheel's centre control module, the bonnet air vents, door mirrors and the brake and water-cooling inlets.



“The main goal is to have a lot of parts in a short time. We can quickly test a wide variety of designs and furthermore, this technology enables us to react swiftly to any changes in the design process.



“The bigger the variety of parts we can test in this facility, the better. It enables us to make much faster progress. The results were excellent, and some were even surprising, because we were looking to push the material to its limits.



“This technology is and will continue to be key in countless fields to make the most complex ideas a reality.”



The final development of the 3D printed parts was on a racing circuit, with CUPRA testing the Leon Competición on the Portimao track in Portugal.



So far, CUPRA has been printing parts for its Leon Competición – its 180mph 335bhp, 2.0-litre touring car inspired by the new Seat Leon family hatchback – and the e-Racer, an electric touring car which does 0-60mph in 3.2 seconds.



CUPRA has released footage of the printing and test processes of the project, which is in partnership with HP.



Virginia Palacios, head of Systems Product Management, 3D Printing & Digital Manufacturing, HP Inc, said: “The work with CUPRA demonstrates the power of 3D printing and digital manufacturing – changing the way the world designs and manufactures.




“3D printing is going to signal a turning point in the automotive industry by accelerating lead times and HP 3D technology is helping designers create parts that could not be produced with other technologies.”




Jodie Davies- photos Cupra





Permanent-URL: http://www.automobilsport.com/cupra-3d-printing-boost-speed-safety-efficiency---205524.html

27.03.2020 / MaP

More News

The world’s first aerogels made from scrap rubber tyres
19.03.2020
Photo caption: A team of NUS researchers led by Assoc Prof Duong Hai-Minh (front row, first from left) and Prof Nhan Phan-Thien (front row, centre), developed the world’s first aerogels made from scrap rubber tyresA team more >>
Porsche presents innovative 3D-printing technology for bucket seats
17.03.2020
Concept study on individual seat fitting inspired by motor sportsPorsche is revolutionising sporty seating: the company presents an innovative alternative to conventional bucket seat upholstery with the concept study “3D-printed bodyform full-b more >>
BradyPrinter - Identify cables 3 times faster
14.03.2020
Experienced operators can print and manually apply a flag label on a cable in 15 seconds. With the new BradyPrinter A5500 Flag Printer Applicator they can significantly increase production output by flagging cables in 5 seconds. more >>
New Ford Tec steers clear of ditches and drops to help drivers stay on the road
13.03.2020
Driving in rural areas can be tricky when unmarked road edges become ragged and give way to open land, muddy ditches and sheer drops.  *Driving at night – in unlit areas especially – can be a challenge.Most road fat more >>
Fast Company announces CAKE among the WORLD'S MOST INNOVATIVE COMPANIES
10.03.2020
CAKE, the Swedish manufacturer of lightweight electric off-road performance motorcycles, has been selected to the list of the Most Innovative Transportation Companies 2020 by Fast Company -The only 2 wheeled company to make the list. CAKE is among t more >>
FPT Industrial F28 “Diesel of the Year®” 2020 displayed at Conexpo Show
10.03.2020
The “Diesel of the Year®” landed in Las Vegas for its premiere in North America. The F28 was unveiled last November and has been recently awarded “Diesel of the Year®”. This prestigious award is given on an annual basis by Diesel magazine and recognizes the best innovation in the development and manufacturing of diesel engines in all industrial and automotive app more >>
SEAT will be able to detect if you fall asleep at the wheel
06.03.2020
    SEAT working with technology start-ups to drive better road safety    Computer Artificial Intelligence ensures driver is awake and not distracted    36% of collisions are due to driver distraction or tiredness    Active glazing technology another route of development for future SEAT more >>
The Goodyear reCharge Concept - Making Tyre Changing Easy with Customized Capsules that Renew your Tyres
04.03.2020
The Goodyear reCharge is a revolutionary self-regenerating concept tyre that can adapt and change to meet individual mobility needs."Goodyear wants the tyre to be an even more powerful contributor to answering consumers' more >>
FPT Industrial joins European Research Project for Nextgeneration batteries
03.03.2020
FPT Industrial is participating in the European battery research project SeNSE, officially launched last month. Together with five other industrial companies and five research institutes, the Brand will work over the four coming years to find solut more >>
From bottle to fabric: Seat upholstery made of PET
25.02.2020
New Audi A3 with sustainable interior concept        Up to 45 PET bottles with a capacity of 1.5 liters used per seating system        Many additional components made from secondary raw mate more >>
A Porsche as personal as your own fingerprint
24.02.2020
 Innovative printing method for body paintworkIt's already the case that hardly any Porsche is the same as another. But from now on, the 911 can even be as unique as the papillary lines on a human fingertip. Using an innovative direct printing meth more >>
Hyundai and Kia Develop World’s First ICT Connected Shift System
20.02.2020
    Information and communication technology (ICT) automatically shifts to optimal gear based on road and traffic conditions ahead    Improves driving comfort and fuel efficiency by minimizing unnecessary shifts through predictive gear-shifting control system    Future developments to include consideration more >>
Porsche Consulting: Three new offices and an innovation lab
18.02.2020
   Management consultancy grows revenues by 17.4 percent and opens three new officesPorsche Consulting recorded revenues of €203.1 million for 2019, which represents a year-over-year growth rate of 17.4 percent and a new a more >>
SEAT - This is how you explore the future
17.02.2020
A global technology hub    SEAT and Xplora are looking for innovative solutions in one of the world's biggest technology hubs    In Tel Aviv (Israel) there are 6,600 startups, 800 of which are dedicated t more >>
BMW i Ventures Announces Investment in AutoFi.
13.02.2020
BMW i Ventures announced today an investment in AutoFi, a technology company transforming the way cars are bought and sold.Headquartered in San Francisco, CA, AutoFi is a retail platform that allows car buyers to purchase and finance a car from a variety of financial institutions within or outside the dealership. Thanks to AutoFi’s deep integration more >>
Cupra - A 3D printed racecar
06.02.2020
    CUPRA commits to 3D printing in the development of the new Leon Competition    The door mirror, air intakes and cooling intakes have been produced with state-of-the-art HP Multi Jet Fusion technology& more >>
Hengst: Premiere for Blue.on in the new Opel Astra
05.02.2020
Lifetime functional safetySystem has won two German innovation awardsThe concept of the Blue.on filter consists of a housing, a pipe with integrated filter bypass and no more >>
Newly established SKODA AUTO DigiLab India and Software Development Centre support SKODA-led INDIA 2.0 project
31.01.2020
› ŠKODA AUTO DigiLab India is the fourth innovation hub, joining those based in Prague, Tel Aviv and Beijing› Dedicated Software Development Centre in Gurugram and P more >>
Ford develops 3D-printed locking wheel nuts to thwart thieves
30.01.2020
    Ford-patented unique lock nuts, personalised by owners, could prevent alloy wheel theftsAs car security systems become increasingly more sophisticated, thieves are targeting car parts instead, including alloy wheels. more >>
Lexus releases report on the future of luxury
24.01.2020
    Lexus USA commissioned a study of more than 3,200 Americans from Gen Z to Baby Boomers on what they consider ‘luxury’    Exceptional experiences and quality top the list of demands    New must-haves include time for the occasional “digital detox”, a desire to be unique and an increased focus more >>
Lexus Zero Gravity Concept shoots for the moon
23.01.2020
    All the thrill of high-speed space exploration in Lexus’ new Zero Gravity concept design    Karl Dujardin’s dream machine was the top pick from a series of lunar vehicle ideas from leading international designers and architects    Design sketches developed at ED2, Lexus’ European advan more >>
Lexus Lunar by Yung Presciutti
23.01.2020
Lexus Lunar Design Concepts Zero GravityLexus Lunar is a large-scale vehicle designed for safe lunar exploration. It is divided into two parts: the bottom consists of a platform with six rugged wheels, giving the vehicle the freedom to go whereve more >>
Lexus Moon Racer by Yung Presciutti
23.01.2020
Lexus Lunar Design Concepts Zero GravityThe Moon Racer is a recreational, one-person vehicle, designed to cope with different peaks found across the lunar surface, and to let the user enjoy the effects of low gravity, jumping, climbing, racing and discovering the entire moon. more >>
Lexus Lunar Mission by Yung Presciutti
23.01.2020
Lexus Lunar Design Concepts Zero GravityThe Lunar Mission is designed for people to fly to, then walk on the moon. The body design integrates a liquid side form which can reflect the universe during flight.The wings more >>
Lexus Lunar Cruiser by Keisuke Matsuno
23.01.2020
Lexus Lunar Design Concepts Zero GravityThe Lunar Cruiser is a multi-purpose lunar vehicle for use on land and in the sky.Its large tyres provide a comfortable ride, even over rough terrain. more >>
Bouncing Moon Roller by Julien Marie
23.01.2020
Lexus Lunar Design Concepts Zero GravityThe Bouncing Moon Roller is protected by a flexible graphene nanotube-based bubble. This structure allows the vehicle to jump and roll at any angle over a wide range of terr more >>
Lexus Cosmos by Jean-Baptiste Henry
23.01.2020
Lexus Lunar Design Concepts Zero Gravity   Lexus Cosmos is a transportation concept designed for travelling both in space and across the lunar surface. It has a fully sculpted glass form that functions both as a massive obser more >>
Lexus Lunar Design Concepts Zero Gravity by Karl Dujardin
23.01.2020
The future of Lexus is captured in the design of Zero Gravity, which reinterprets the signature Lexus spindle form as a three-dimensional architecture.   Sharp and squared edges are transformed into fluid, curved surfaces to create more >>
INCIT-EV Project: Innovative electric charging solutions to be tested in Europe
22.01.2020
The INCIT-EV[1] project aims to encourage the development of electromobility in Europe through field experiments.    7 innovative charging technologies for electric vehicles will be tested in chosen locations in Europe.    Groupe Renault is coordinating this initiative, which has support from the European Comm more >>
BMW i Ventures Announces Investment in Alitheon.
15.01.2020
BMW i Ventures announced today an investment in Alitheon, an optical AI software creator and deep-tech startup developing generative engineering software aimed at automating the product development process. Alitheon will use the new funding to expand its FeaturePrint™ technology across the defense, aerospace, aviation services, automotive, semicon more >>
FORD Welcome to the Future - Connected Car Technology Now Warns Drivers of Dangers Around the Corner
14.01.2020
•    Local Hazard Information (LHI) marks a significant step on the journey towards a connected transport infrastructure by helping drivers prepare for and potentially avoid dangers on the road.•    New Local Hazard Information offers drivers advance warning of potential dangers ahead.•    The more cars more >>
Volkswagen and diconium further expand their corporation
10.01.2020
    Shareholders agree that the Volkswagen stake in diconium should be boosted from 49 to 100 percent    diconium contributes further key know-how to the Volkswagen Group’s Car.Software organization and strengthens Volkswagen’s capabilities in the field of digital sales solutions more >>
A glimpse into future missions for the Cursor X at CES 2020
07.01.2020
From January 7th to 10th, FPT Industrial, the brand of CNH Industrial dedicated to the design, production and sale of powertrains for on and off-road vehicles, marine and power generation applications, will unconventionally welcome and wow visitors to its stand (Convention Center, South Hall 2, Booth 26236) at CES 2020 in Las Vegas. more >>
Hitachi Automotive Systems Americas and TomTom Collaborate on a Proof of Concept for Developing Next-Gen Smart Navigation Solution
07.01.2020
Hitachi Automotive Systems Americas, Inc. and TomTom (TOM2), the location technology specialist, today announced that they are collaborating on a proof of concept for the development of a new real-time hazard service for navigation and Advanced Driver Assistance Systems (ADAS). more >>
In collaboration with the AVATAR films, Mercedes-Benz is developing a vision for the future of mobility: the VISION AVTR
07.01.2020
Consumer Electronics Show (CES) 2020 Las VegasAt CES 2020, the inventor of the automobile will be giving an outlook on the sustainable mobility of the future with the Mercedes-Benz VISION AVTR. more >>
AVL Adds Rohde & Schwarz GNSS Stimulation to Vehicle Test Environment
07.01.2020
GNSS signals (for example GPS signals) are of major importance for positioning and tracking, orientation and safety-related information, such as congestion, in road traffic.   A collaboration between AVL and Rohde & Schwarz, two of the more >>
Groupe Renault and Otodo develop new solution linking cars and homes
06.01.2020
Groupe Renault is developing a solution enabling automatic and secure interaction and communication between cars and connected objects in homes.    Otodo, a young French company pioneering smart-home connectivity, will deliver the secure link between the ve more >>
FPT Industrial to acquire Dolphin N2 startup to develop disruptive powertrain technology
19.12.2019
FPT Industrial, brand of CNH Industrial dedicated to the design, production and sale of powertrains for on and off-road vehicles, marine and power generation applications, today announced its agreement to acquire 100% of Dolphin N2, a spin-out more >>
Honda’s Vision of the Future Integrates CASE Technologies into New Products and Services at CES 2020
18.12.2019
   "Smartphone as Brain" brings advanced connectivity to motorcycles    Honda Xcelerator showcases "Industrial Innovation" with demos from new startup partners    Honda Personal Assistant voice-enabled AI assistant seamlessly connects devices and controls cabin functions    Honda more >>
2001-2021 copyright automobilsport.com