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Cupra’s unique 3D printing technique for race cars components

27 March 2020

Cupra with a revolutionary 3D printing technique
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Despite still being considered a newbie in the automotive industry, CUPRA is steadily moving towards the top 10 innovative carmakers. That’s due to the unique 3D technique the brand uses to create components for some of its cars. This method is mostly utilized in the creation of side doors mirrors, air scoops and cooling vents for CUPRA’s Leon Competiciónracig vehicle.

Thanks to the innovative technology, CUPRA’s racing team has managed not only to significantly optimize the car’s fuel consumption but also to improve safety and top speed. Each one of these characters plays a major role in the racing segment and define the capabilities of the track vehicle.

The entire 3D printing could tale up to 20 hours, but it gives CUPRA the chance to create and test not just one but a total of 6 different component prototypes. When ready, the 3D printed parts are mounted on a test vehicle and put through a series of tests in the company’s wind tunnel – used to test the aerodynamic capabilities of each car. The wind’s speed could reach up to 280 km/h making it difficult for the car to move.

During the testing period, a multitude of sensors, mounted all over the car’s body gather information about the air impact on the car’s aerodynamics and fuel economy.

3D technology also enables the test of more than one component at the same time – significantly easing the process of car production.

For now, CUPRA uses the 3D print for is e-Racer and Leon Competición machines. However, if everything goes according to the company’s plans, this method will be applied to the rest of the product portfolio of the Spanish marque.


Author: D. Ilieva