This Breathtaking Bugatti Hypercar Reveals its 3D Printed Secrets

Pioneering 3D printing techniques help slash weight from this 1,500-horsepower beast.

Dan Carney, Senior Editor

May 17, 2021

10 Slides
02_bugatti-bolide_3d-print.jpeg
Bugatti's Bolide track car with its bodywork removed to reveal the technology beneath.Bugatti

With its multi-million dollar technical showpiece cars, Bugatti is uniquely positioned to pioneer technologies that are cost-prohibitive for regular carmakers. One such example is the use of 3D printing to fabricate fantastically light and strong components that probably each cost as much as an ordinary Honda Civic.

Researcher Henrik Hoppe is aiming to prove some of his design concepts using the Bugatti Bolide, a race track-only derivative of the company’s flagship Chiron super sports car. Hoppe seeks to identify the commercial and technological potential of functional 3D-printed metal components for automotive manufacture, with applied targeting at specific parts. Previously, these types of components were used predominantly in the aerospace sector.

The goal is to optimize the design of 3D printed components using a complex, bone-like structure to enhance components with complex three-dimensional designs. The characteristics of the resulting parts include thin 0.4mm walls, a hollow interior, and fine branching.

“We will continue to reduce the weight of our cars while increasing their innovative features in every conceivable area,” explained Hoppe. The street-legal production Chiron features a metal 3D-printed water-carrying high-pressure pump console next to the transmission fluid reservoir.

Related:Magneti Marelli’s First-Ever Carbon Fiber Steering Knuckle Slashes Weight

About the Author

Dan Carney

Senior Editor, Design News

Dan’s coverage of the auto industry over three decades has taken him to the racetracks, automotive engineering centers, vehicle simulators, wind tunnels, and crash-test labs of the world.

A member of the North American Car, Truck, and Utility of the Year jury, Dan also contributes car reviews to Popular Science magazine, serves on the International Engine of the Year jury, and has judged the collegiate Formula SAE competition.

Dan is a winner of the International Motor Press Association's Ken Purdy Award for automotive writing, as well as the National Motorsports Press Association's award for magazine writing and the Washington Automotive Press Association's Golden Quill award.

AstonMartinVanquish_©AndyMorgan_025_copy_2.JPG

He has held a Sports Car Club of America racing license since 1991, is an SCCA National race winner, two-time SCCA Runoffs competitor in Formula F, and an Old Dominion Region Driver of the Year award winner. Co-drove a Ford Focus 1.0-liter EcoBoost to 16 Federation Internationale de l’Automobile-accredited world speed records over distances from just under 1km to over 4,104km at the CERAM test circuit in Mortefontaine, France.

He was also a longtime contributor to the Society of Automotive Engineers' Automotive Engineering International magazine.

He specializes in analyzing technical developments, particularly in the areas of motorsports, efficiency, and safety.

He has been published in The New York Times, NBC News, Motor Trend, Popular Mechanics, The Washington Post, Hagerty, AutoTrader.com, Maxim, RaceCar Engineering, AutoWeek, Virginia Living, and others.

Dan has authored books on the Honda S2000 and Dodge Viper sports cars and contributed automotive content to the consumer finance book, Fight For Your Money.

He is a member and past president of the Washington Automotive Press Association and is a member of the Society of Automotive Engineers

Sign up for Design News newsletters

You May Also Like