The fact that metal additive-manufacturing technology is accelerating industrial development in the automotive sector is shown by the repeated success of the Bugatti sports car brand in achieving “consistent function integration
and significant performance optimisation of components”.

A number of metal 3-D printed functional components have been used by Bugatti, and all were produced on machines developed and manufactured by SLM Solutions AG (www.slm-solutions.com), based in Lübeck, Germany.

Moreover, the effectiveness of such components was verified by the dynamic bench testing of a Bugatti brake caliper, said to be “volumetrically the largest functional titanium component built with selective laser melting to be tested.” The video can be seen at the Web site (https://youtu.be/hPkY8nBWxoU).

Frank Götzke, head of new technologies at Bugatti, said: “This is proof that additively produced metal components can meet the extreme strength, stiffness and temperature requirements needed when encountering speeds of over 375kph, braking forces of 1.35g and brake disc temperatures up to 1,100°C.”

Further tests on the caliper showed that the AM material had a tensile strength of 1,250N/mm2 and a density of over 99.7%.

The component was manufactured in the aerospace alloy Ti6Al4V in conjunction with Fraunhofer IAPT (formerly Laser Zentrum Nord) and Bionic Production AG on an SLM500 featuring four 400W lasers.

Bugatti says it uses selective laser melting not only for ‘lightweighting’ but also for optimised functional capabilities.

Mr Götzke added: “We always strive for absolute perfection, both stylistic and technical, as well as considering the perfect synergy of both elements — the tradition of Ettore Bugatti that we uphold.”

An active spoiler bracket, manufactured on an SLM500, represents this combination, helping the 1,500hp car to reach speeds of 400kph (just under 250mph) in 32.6sec — and then come to a stop in just 9sec.

Bugatti teamed up with Siemens to optimise the bracket for production and reduce the number of iterations needed to also optimise it for weight and rigidity.

Using 3-D printed titanium with a tensile strength of 1,250MPa and a material density of over 99.7%, the spoiler bracket was reduced by 5.4kg (a weight reduction of 53%), without sacrificing any functional benefits.