R&D Archives

The 235 km/h hurricane in the room

Nobody can see it, but it is a factor in a car’s fuel consumption, safety and comfort. It’s called aerodynamics, or the study of how air moves around solid objects. In the automotive world, its application is very practical: reducing a car’s resistance to wind. And all this is tested in its ‘temple’, the wind tunnel. This is how it works.

A hurricane in the room
Typically, prototypes are placed in the middle of a chamber, securely kept to the floor. Huge fans generate airflow and the vehicles can face winds of up to 300 km/h while sensors study their individual surfaces.

The air travels in a circular motion, depending on the size of the rotor and blades. Needless to say, when it’s blowing at full power, no one will be allowed inside the chamber as they would literally get blown out of it.

The car’s resistance data is displayed on the computer screens. Hundreds of numbers to be interpreted and compared to even the smallest variable to improve aerodynamics. Every millimetre of each part is key, since it is not only possible to reduce consumption, but also to increase stability, comfort and safety.

Shaping to go faster
Wind tunnels, while primarily used for development of future models, are also valuable for racing cars. While the goal in aerodynamic efficiency for production models is to lower fuel consumption and improve stability, when it comes to racing cars, optimising the bodywork to achieve higher speeds is the aim.

SEAT wnd tunnel — *The performance of rear wings, for example, can be optimised for the best downforce.*

CUPRA Racing’s Head of Technical Development, Xavi Serra, explains: “We want the new CUPRA Leon Competicion to have less air resistance and more grip when cornering. First, they will have to compete against the wind. Here we measure the parts on a 1:1 scale with the real aerodynamic loads and we can simulate the real contact with the road. This gives us the result of how the car will perform on the track.”

235 km/h standing still
The facilities where the CUPRA engineers test their prototypes are among the most complete and innovative. They have a special feature that makes the tests seem as if they are made in near-real conditions. However, instead of the car travelling at up to 235 km/h, the same effects are achieved by making the air travel at those speeds.

“The most important thing is that we can simulate the road. The wheels turn thanks to electric motors that move belts under the car,” said Wind Tunnel engineer Stefan Auri.

After hundreds of measurements, the results are compared with the car’s previous generation. “In this sense we’re satisfied; we’ve lowered the drag and improved the downforce, so it’s more efficient than the previous model, which will give us better lap times on the track,” said Xavi, adding that the data obtained will also be used to improve the new CUPRA models.

Supercomputer crunches numbers
The wind tunnel is not the only tool for improving aerodynamics. Supercomputing also plays a key role. When a model is in the early stages of development and there is not yet a prototype to study in a wind tunnel, 40,000 laptops working in unison are put to the service of aerodynamics. This is the MareNostrum 4 supercomputer, the most powerful in Spain and the seventh in Europe. Scientists around the world use it to carry out all kinds of simulations, and in the case of a collaboration project with SEAT, its computing power is used to battle the wind.

Watch: Onboard a race-spec Seat Cupra around Sepang Circuit!

Moving to the next chapter of the BMW Efficient Dynamics story

BMW Efficient Dynamics technology was initiated in 2007 with the objective of consistently reducing fuel consumption – and thereby CO2 emissions – on the one hand, while steadily enhancing driving dynamics on the other. Generally, when pursuing lower fuel consumption goals, the trade-off has been in performance but that would not be acceptable to BMW engineers.

As a result, Efficient Dynamics is now a fundamental link in the DNA of all BMW models and one of the key reasons why the BMW Group will be able to meet the European Union’s CO2 targets in full.

Technical measures covering every area
The Efficient Dynamics approach systematically optimizes every aspect of the vehicle, not just the powertrain. On the aerodynamics side, active air flap control is now in its third generation, while the new iX3 (due to be launched by the end of 2020) will be fitted with the latest generation of BMW aerodynamic wheels.

The technology behind the new wheels has been further refined, resulting in a 5% reduction in drag coefficient compared to conventional X3 wheels plus a 15% weight saving over the previous BMW aerodynamic wheel type.

Such significant steps forward have been achieved thanks to heavy investment in the necessary aerodynamics R&D infrastructure over recent years. The most aerodynamically efficient current model overall, the new 3-Series Sedan, has a Cd of just 0.23, earning it the title of ‘best in segment’.

Intelligent lightweight design has also led to some major efficiency-boosting advances. This has made it possible to reduce the weight of models from one generation to the next, despite increases in size and safety enhancements. Optimizing structures and employing the ideal materials in every area of a vehicle are key to attaining the goals that have been set.

The wide range of powertrain systems on offer also plays a fundamental role in the Efficient Dynamics concept. From highly efficient combustion engines with 48V electrical systems to plug-in hybrids and all-electric vehicles – all are underpinned by the basic principle of Efficient Dynamics: minimize the input while maximizing the output.

The advent of 48V mild hybrid technology greatly expands the possible uses of Brake Energy Regeneration. This technology made its debut in the four variants of the 520d last year and are now being extended to the 3-Series, X3 and X4 ranges.

Hydrogen fuel cells in future
The BMW i Hydrogen NEXT – unveiled to the public at the 2019 Frankfurt Motor Show as a technology demonstrator – represents a potential fourth pillar in the company’s powertrain portfolio. The BMW Group has been working with the Toyota Motor Corporation on fuel cell technology since 2013. The underlying conditions for supplying ‘green’ hydrogen are not yet in place, however, meaning it will still be some time before the BMW Group brings out a production vehicle with this technology on board.

Systematic roll-out with clear benefits
As a result of the continuously evolving package of technological measures, fleet consumption and CO2 emissions have been cut by more than 40% over the last 13 years. What is more, the BMW Group will comply in full with the European Union’s CO2 targets, thanks in part to the rigorous deployment of BMW Efficient Dynamics innovations as standard across all model series. With ongoing electrification of the range, CO2 emissions in 2020 will be 20% lower again thant the figure for 2019.

First look at the hydrogen fuel cell powertrain being developed by BMW and Toyota

First new Aston Martin engine in over 50 years starts test runs (w/VIDEO)

Aston Martin has revealed further details of its in-house designed V6 engine, created initially for deployment in a new range of mid-engined sportscars, starting with the Valhalla from 2022. Codenamed TM01 – celebrating Aston Martin’s illustrious engineer of the 1950s and 1960s, Tadek Marek – the engine has already undergone a series of extensive testing sessions on the dyno, as the team make progress towards creating the luxury British brand’s first in-house designed engine since 1968.

Confirmed today as a 3.0-litre turbocharged V6, the full powertrain will be electrified – an aspect that has been key to the engine’s development from day one. In parallel to the tests shown today, Aston Martin is developing a new range of hybrid systems that will ensure that the complete unit will become the most powerful in the Aston Martin range when on sale. The final power and torque figures for each application of this powertrain will be determined by the desired characteristics of each product it serves and confirmed at the time of launch.

Following the Valkyrie – the brand’s first mid-engined hypercar – many key learnings have been directly applied to this project. As a result, the decision to develop the engine with a ‘hot V’ structure was clear from the start, with the configuration allowing for this compact engine to weigh less than 200 kgs.

Higher engine speeds, in combination with the benefits of electrification, will offer the performance characteristics of a mid-engined sportscar on an extreme level. Naturally, the engine will be positioned directly behind the driver’s cabin and equipped with a dry sump system to guarantee the lowest possible centre of gravity. The system will also deliver exceptional lubrication performance during on-limit, high-speed cornering. Despite the overt nature of this powertrain, the engine is designed to meet all future emission requirements for Euro7.

“This project has been a great challenge from the start. Putting a team together to deliver what is going to be the future power of Aston Martin has been an honour. From the very beginning, we have had the freedom to explore and innovate in a way that we have not been able to do so in a very long time. Most importantly, we wanted to create something that is befitting of the TM01 nameplate and create something that would have impressed our predecessor and pioneering engineer, Tadek Marek,” said Joerg Ross, Powertrain Chief Engineer.

Max Verstappen and Alex Albon test-drive the Aston Martin Valkyrie hypercar

Goodyear reCharge tyre creates its own treads when needed (w/VIDEO)

Ever since the pneumatic tyre was invented, motorists have had to live with the possibility of the air inside leaking out due to being punctured by a nail or damage from hitting a pothole. Loss of air pressure, which is what keeps the tyre in its hard shape to roll along, means the tyre cannot be used and has to be replaced. Not something you want when you are on the way to a meeting or a holiday resort.

Various solutions have been developed over the years which try to keep the tyre usable even when the air is gone. Run-flat tyres are capable of continuing even when deflated, though at limited speeds and for a limited distance. Obviously, they need to be replaced or repaired as soon as possible.

More specialised tyres for off-road use have flexible foam inside which can maintain the tyre shape even when air has leaked out.

Regenerating the tread
Now Goodyear is taking another approach with a prototype tyre it calls recharge. This is reloadable and has a tread compound that can be recharged with individual capsules, radically simplifying the process of replacing your tyres.

Filled with a customized liquid compound, these capsules allow the tread to regenerate and the tyre to adapt over time to climatic circumstances, road conditions, or simply how you want to travel. Thanks to artificial intelligence, a driver profile would be created around which the liquid compound would be customized, generating a compound blend tailored to each individual.

The compound itself would be made from a biological material and would be reinforced with fibres inspired by one of the toughest natural materials in the world – spider silk. This would make it both extremely durable and 100% biodegradable.

No maintenance needed
In addition to radically simplifying the process of replacing tyres using the rechargeable capsules, the tread would be supported by a lightweight, non-pneumatic frame and tall-and-narrow shape. This is a thin, robust low-maintenance construction that would eliminate the need for pressure maintenance or downtime related to punctures.

“Goodyear wants the tyre to be an even more powerful contributor to answering consumers’ specific mobility needs,” said Mike Rytokoski, Vice-President and Chief Marketing Officer, Goodyear Europe, “It was with that ambition that we set out to create a concept tyre primed for the future of personalized and convenient electric mobility.”

Recharge is just a concept for now although it could become one of the features of tyres of the future. Only thing is, if the tread can be regenerated, then the tyres doesn’t need to be replaced. That’s good for the environment but is it going to be good for company business?

Goodyear Eagle F1 range in Malaysia widens with more choices

New Ford technology can prevent ‘car dooring’ by cyclists (w/VIDEO)

Many cars nowadays come with a sensing system that monitors the area along the sides of the car which are in the driver’s blind spot. The sensors detect the presence of another car or motorcyclist and alert the driver by a flashing light on the mirror or on the instrument panel. The warning can prevent a collision if the driver had been intending to change lanes or turn.

Volvo (while it was in the Ford Group) developed this active safety system that came to be called the Blind Spot Information System or BLIS. Naturally Volvo models were the first to have BLIS from 2007 and Ford too adopted the system on many of its models as an optional or standard feature.

*Ford BLIS warning flashes on the door mirror if there is another vehicle or motorcyclists in the blind spot.*

Eventually other manufacturers also had similar systems and today, the sensors also detect cross traffic approaching as the vehicle reverses out of a parking bay. This is especially useful as the driver may not be able to see either side due to the view being blocked by other adjacent vehicles.

However, BLIS works only when the vehicle is moving and now Ford has gone further in this area by developing new technology which can reduce accidents caused by drivers or passengers opening their doors as a cyclist is approaching. Although they should first open the door slightly and look to the back first, many just open it suddenly and a cyclist might not be able to stop in time.

3,500 accidents in one year
While this sort of accident may not be so common in Malaysia, there are thousands such accidents in Europe every year. In 2018 alone, 3,500 ‘car dooring’ accidents occurred in Germany. This problem is expected to get worse as more people choose to cycle and ride e‑scooters in cities.

Ford’s new technology is called Exit Warning and provides visual and audible alerts to road users and vehicle occupants when it detects that opening the door of a parked car might cause a collision. It could also prevent a vehicle door from opening into someone’s path.

How it works
Many Ford vehicles already have sensors and technology that can automatically detect and brake for cyclists ahead and as mentioned earlier, BLIS lets drivers know when other road-users are in their blind spots.

Using these existing sensors, Exit Warning analyses and understands the movements of approaching road-users – whether they are riding a bicycle or an e-scooter – on both the driver and passenger sides of the vehicle. If the system detects that opening the vehicle door could cause a collision, an alarm sounds to warn the driver or passenger of the danger.

To attract attention, bright red LEDs on the wing mirror also begin to flash as a visual warning for cyclists and a strip of red LEDs along the inner trim of the door – that becomes visible when the door is opened – provides further warning for passing road-users.

For engineers are also testing a new mechanism for the car door that momentarily prevents it from fully opening until the Exit Warning system determines the passing road-user is safely clear of the vehicle. Of course, the vehicle occupant will be able to manually override this feature in an emergency.

Following testing with drivers and cyclists from within Ford, the engineers will be conducting customer clinics in coming months. Part of the testing will be to ensure that the technology accommodates road-users in different markets, taking into account right-hand and left-hand drive vehicles as well as different road and lane layouts.

Fostering harmony between road-users
Ford’s ‘Share The Road’ campaign seeks to foster harmony between road-users and underlines the company’s belief that enabling more people to cycle safely, especially for short journeys, benefits everyone.

The company recently highlighted the challenges of communication between drivers and cyclists – and how smart thinking could potentially ease tensions and reduce accidents. Its prototype ‘Emoji Jacket’ is a one‑of‑a‑kind wearable that features a brightly lit LED mesh panel to display emojis, indicators and the hazard warning symbol. The prototype jacket enables cyclists to more easily and clearly signal their intent – and their feelings – to drivers and other road-users.

Visit www.sdacford.com.my to know more about the safety technologies in today’s Ford models.

Ford organises Driving Skills for Life to promote safety

BMW iNEXT undergoes extreme testing conditions in Africa

On its way to being ready for production, the BMW iNEXT is completing additional vehicle testing under particularly demanding conditions. Intensive test runs in the freezing cold at the polar circle are now being followed by a contrasting program in the Kalahari in southern Africa.

In addition to extreme heat and solar radiation, permanent dust formation and off-road terrain with its sand, pebble and gravel tracks pose exceptional challenges for the BMW Group’s technology flagship.

The test drives through the desert and savanna regions in the northwest corner of South Africa are in temperatures that would drain any mobilephone battery in no time at all. This puts a severe test on the integrated cooling concept for the high-voltage battery, the electric motor and the vehicle electronics.

During extensive heat tests, the car is repeatedly exposed to the heat of the sun for hours and later cooled down. In this way, the developers test not only the operability of the electrical systems but also the temperature stability of the materials used in the interior.

Moreover, the interior air conditioning, which operates by means of thermal pump technology, its control system and all further components of the electronics, are subjected to the extreme conditions of the desert climate.

Every part and system stress-tested
In this literally hot phase of the product development process, not only do the drive and suspension components of the iNEXT – a car designed for all-electric mobility – have to provide proof of their functional safety, durability and reliability, but also the car’s bodywork, interior, driver assistance systems and digitalisation technology.

The ‘hot climate’ tests are an integral part of a both extensive and varied development and test program. Prototypes are subjected virtually in time-lapse to the stress of an entire car’s service life.

Real-world conditions
Like every new BMW model, the prototypes are also driven at the proving ground at Miramas in southern France, the Nurburgring Nordschleife and other racetracks as well as the Winter Centre in Sweden.

With high-speed operation, stop/go traffic, extreme temperatures below and above zero, testing on ice and snow as well as desert sand and gravel, the pre-production cars are put through a concentrated form all of the challenges an automobile may face in everyday traffic over a period of many years.

Fifth generation BMW eDrive technology
Featuring fifth-generation BMW eDrive technology, the iNEXT is said to set new benchmarks in sportiness, efficiency and range in a battery-powered automobile. The car’s suspension control and driver assistance systems pave the way for a further step towards autonomous driving. Current innovations in the field of operation and digitalisation also underscore the future-oriented character of the iNEXT.

Production of the iNEXT will commence at the BMW Dingolfing plant in 2021. Designed as a modern Sports Activity Vehicle, the new model combines the latest innovations defined by the BMW Group in its corporate NUMBER ONE > NEXT strategy for the future fields D-ACES (Design, Autonomous, Connected, Electrified und Services).

5th generation BMW eDrive technology to debut in iX3 next year

Using information and communication technology (ICT) to enhance motoring

The two carmakers in the Hyundai Motor Group – Hyundai Motor Company and Kia Motors Corporation – have jointly developed the world’s first predictive Information and Communication Technology (ICT) Connected Shift System to enhance motoring. The system is also in line with autonomous technology, which is developing day by day.

The system enables the vehicle to automatically shift to the optimal gear after identifying the road and traffic conditions ahead. While the technologies used to automatically shift depend on drivers’ preferences, such as Smart Drive Mode – available on most current Hyundai and Kia models – ICT Connected Shift System is the first ICT to automatically shift the gear according to road and traffic conditions.

The ICT Connected Shift System uses intelligent software in the Transmission Control Unit (TCU) that collects and interprets real-time input from underlying technologies, including 3D navigation equipped with a precise map of the road as well as cameras and radar for smart cruise control. The 3D navigation input includes elevation, gradient, curvature and a variety of road events as well as current traffic conditions. Radar detects the speed and distance between the vehicle and others, and a forward-looking camera provides lane information.

Using all of these inputs, the TCU predicts the optimal shift scenario for real-time driving situations through an artificial intelligence algorithm and shifts the gears accordingly. For example, when a relatively long slow-down is expected and the radar detects no speed irregularities with the car ahead, the transmission clutch temporarily switches to neutral mode to improve fuel efficiency.

During testing on a road with many curves, the frequency of shifts in cornering was reduced by approximately 43% compared to vehicles without the system. Accordingly, the system also reduced the frequency of brake operation by approximately 11%, minimizing driving fatigue and brake wear.

When rapid acceleration was required to enter a highway, the driving mode automatically switched to Sport Mode at the merge, making it easier to join the traffic flow. After merging with traffic, the vehicle automatically returned to its original driving mode, enabling safe and efficient driving.

In addition, engine braking automatically occurred upon release of the accelerator pedal by determining speed bumps, downhill slopes and location of the speed limit change on the road. The changes in distance from the front car were detected by the front radar to adjust appropriate transmission gear automatically improved driving quality.

The ICT Connected Shift System will deliver both improved fuel efficiency and a stable driving experience in the era of autonomous vehicles by providing improved performance in response to real-time road and traffic conditions.

Some 40 major patents in South Korea and abroad for the system which both companies plan to offer on their future models.

Details of the all-new Kia Sorento’s platform and powertrain revealed!

Hyundai Motor Group chooses Canoo platform for future EV models

The Hyundai Motor Group (HMG) will collaborate with Canoo, a Los Angeles-based company creating electric vehicles (EVs) for subscription only, to jointly develop an EV platform based on Canoo’s proprietary skateboard design for future Hyundai and Kia models.

As part of the collaboration, Canoo will provide engineering services to help develop a fully scalable, all-electric platform to meet both Korean carmakers’ specifications. HMG expects the platform to help facilitate its commitment to delivering cost-competitive electrified vehicles — ranging from small-sized EVs to Purpose-Built Vehicles (PBV) — that can meet diverse customer needs.

Canoo’s skateboard platform houses the most critical components of the vehicle with a strong emphasis on functional integration, meaning all components fulfill as many functions as possible. This feat of engineering reduces the skateboard size, weight and total number of parts, which ultimately provides more interior cabin space and a more cost-effective EV offering. In addition, the skateboard is a self-contained unit that can support any cabin design.

HMG envisions an adaptable all-electric platform using Canoo’s scalable skateboard architecture to allow for a simplified and standardized development process for Hyundai and Kia electrified vehicles, which is expected to help reduce cost that can be passed along to consumers. It also aims to reduce complexity of its EV assembly line, allowing for rapid response to changing market demands and customer preferences.

With this collaboration, Hyundai Motor Group doubles down on its recent commitment to invest US$87 billion (about RM360.3 billion) over the next 5 years for future growth. As part of this drive, Hyundai plans to invest US$52 billion (RM215.4 billion) in future technologies through 2025, while Kia will invest US$25 billion (RM103.5 billion) in electrification and future mobility technologies, aiming for eco-friendly vehicles to comprise 25% of its total sales by 2025.

“We were highly impressed by the speed and efficiency in which Canoo developed their innovative EV architecture, making them the perfect engineering partner for us as we transition to become a frontrunner in the future mobility industry,” said Albert Biermann, Head of Research & Development, Hyundai Motor Group. “We will collaborate with Canoo engineers to develop a cost-effective Hyundai platform concept that is autonomous ready and suitable for mass adoption.”

Hyundai Kia concept EV — *Future Hyundai and Kia electrified models will sit on the Canoo skateboard.*

Canoo unveiled its first electric vehicle for subscription only in September 2019, just 19 months after the company’s founding in December 2017. The company’s proprietary skateboard architecture, which directly houses the batteries and electric drivetrain, has enabled Canoo to reimagine EV design in a way that challenges traditional automotive shape and functionality.

The company recently opened the waitlist for its first vehicle. This is a major milestone in its young history and the culmination of the efforts of 300+ experts working to deliver a proof of concept of Canoo’s backbone architectural systems. Canoo’s first vehicle, to be launched in 2021, will be designed for a world in which transportation is becoming increasingly electric, shared and autonomous.

Canoo takes a different approach to EV engineering and marketing

Geely Auto looks at ‘passenger safety’ from a different perspective, aims to make cars ‘healthier’

‘Passenger safety’ in a motor vehicle would be expected to relate to protection during accidents and perhaps the way interior features are designed so as not to cause injuries. Some examples would be the shape of switches and how they project from the dashboard and the type of materials used in areas where the head may hit during a violent accident.

Now, with the outbreak of the coronavirus, one carmaker is adding protection from harmful substances in the air inside the car to ‘passenger safety’ requirements. The carmaker is Geely Auto which has allocated 370 million RMB (about RM220 million) of funding to further the development of ‘healthy, intelligent vehicles’.

The initiative, announced recently not only adds a new dimension to Geely’s understanding of ‘passenger safety’ but also represents a new development direction for automobiles. Until now, addressing air quality in the cabin has been mainly through the use of filters in the ventilation system. Some cars also have a system using nanoe-technology with fine e-ion particles said to be able to deactivate airborne bacteria.

Geely MPV — Geely Auto’s global R&D and design networks will jointly research new environmentally-sustainable materials with anti-bacterial and anti-viral properties which can be used within air-conditioner systems and on frequently touched surfaces such as buttons and handles.

The development of a ‘healthier’ car differs from specialized medical vehicles in that Geely’s products are made for ordinary consumers. A car with comprehensive virus protection not only requires the capability to isolate harmful substances in the air, and it must be able to quickly and effectively purify cabin air for occupants.

Geely Auto’s global R&D and design networks based in Europe, USA and China will jointly move to develop and research new environmentally-sustainable materials with anti-bacterial and anti-viral properties which can be used within air-conditioner systems and on frequently touched surfaces such as buttons and handles.

Geely Auto will make full use of its global R&D system and resources as well as cooperate with professional medical and scientific research institutions to set up special project teams to work on the new research.

Volvo Cars, also a member of the Zhejiang Geely Holding Group like Geely Auto, would be able to contribute a lot of its experience in this area as it would surely have for other safety aspects. For decades, it has paid attention to air quality inside its cars and developed features like the Clean Zone Interior Package and the Interior Air Quality System (IAQS) to maintain high air quality in the passenger compartment. The IAQS is a fully automatic air quality system that separates gases and particles to reduce the levels of odours and contaminants in the passenger compartment.

CleanZone in the Volvo XC60 — *For many years, Volvo Cars has offered air quality systems in its cars.*

“Epidemic prevention is a job that requires the long-term effort of wider society. As the most common mode of transportation, consumers spend a considerable amount time in their cars, akin to a ‘second home’. Only by making healthier products can we meet consumer demand for better quality of life,” said An Conghui, President of Geely Holding Group and President & CEO of Geely Auto Group.

“Based on the automotive industry’s development direction built around electrified, connectivity, intelligence, and shared mobility, auto companies should commit to developing products that help protect the health of drivers and passengers. This will become one of Geely Auto key long-term development objectives,” he added.

Meanwhile, the Geely Holding Group joined hands with the Li Shufu Foundation to set up a special 200 million RMB (about RM118.4 million) fund in support of the new coronavirus prevention and control, with a focus on the mass purchasing of much-needed medical supplies for China in the short term.

CUPRA uses 3D printing for new TCR racing car’s parts (w/VIDEO)

At first glance, it looks like a normal mirror, but it isn’t. It is a 3D-printed part, a technology that CUPRA has begun to implement in the development of the new Leon Competition racing car in collaboration with HP. Greater agility, efficiency and flexibility are the benefits of a system that is set to revolutionise car development.

“For the new CUPRA Leon Competition, we modelled the steering wheel’s centre control module, the bonnet air vents, door mirrors and the brake and water-cooling inlets,” explained Xavi Serra, the Head of technical development at CUPRA Racing. “These parts were produced using HP’s industrial-grade Jet Fusion 5200 3D printing solution and included in the demanding development tests put to the new racing model.”

More efficiency, greater speed
The main goal with this technology, which offers multiple benefits, is to have a lot of parts in a short time. Engineers can quickly test a wide variety of designs and furthermore, since vehicle development is now done in parallel, this technology enables quicker response to any changes in the design process.

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

Wind-tested 3D parts
In TCR competition, the door mirror is a part which, according to the rules, must have the same shape as the production car. But the CUPRA engineers went one step further. “We wanted to add an additional function, which is to cool the driver. We therefore had to design an air intake in the maximum pressure zone to achieve this effect,” said Xavi.

The place where these materials are tested is the wind tunnel, where the 3D-printed parts are verified in exactly the same way as the rest. “The bigger the variety of parts we can test in this facility, the better. It enables us to make much faster progress,” he added.

2020 CUPRA Competition — *The new Leon Competition with its 3D printed parts was tested to the limit on the Portimao track in Portugal.*

As it is a racing car, the final phase of development can only be carried out in one place: the circuit. “The results were excellent, and some were even surprising, because we were looking to push the material to its limits,” the CUPRA engineer reported.

Making complex ideas a reality – fast
“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,” said Palacios, predicting that the technology will continue to be key in countless fields to make the most complex ideas a reality.

Watch: Onboard a race-spec Seat Cupra around Sepang Circuit!

Piston.my

R&D

The 235 km/h hurricane in the room

Moving to the next chapter of the BMW Efficient Dynamics story

First new Aston Martin engine in over 50 years starts test runs (w/VIDEO)

Goodyear reCharge tyre creates its own treads when needed (w/VIDEO)

New Ford technology can prevent ‘car dooring’ by cyclists (w/VIDEO)

BMW iNEXT undergoes extreme testing conditions in Africa

Using information and communication technology (ICT) to enhance motoring

Hyundai Motor Group chooses Canoo platform for future EV models

Geely Auto looks at ‘passenger safety’ from a different perspective, aims to make cars ‘healthier’

CUPRA uses 3D printing for new TCR racing car’s parts (w/VIDEO)

VR technology revolutionises design processes at Hyundai Motor

VISION EQXX does 1,000 kms on a single charge!

Honda and GM to co-develop affordable electric vehicles for sale from 2027

First pictures of electric Rolls-Royce Spectre, to go on sale in 2023

1,600 ps Bugatti Centodieci completes endurance testing, ready for production

Subaru running BRZ prototype in Super Taikyu series to test carbon-neutral fuel

UKM team completes development of two hydrogen fuel cell electric vehicles (FCEVs)

Mazda to use SKYACTIV-D engine with next-generation biofuel in endurance racing

High-performance Lexus V8 modified to run on hydrogen in Toyota-Yamaha project

Pushing prototypes to the limits – and having fun as well

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