BYD Yangwang reveals 3D printed chassis behind U9 Xtreme EV lap record

BYD’s premium electric performance brand, Yangwang, has disclosed new details about the additive manufacturing techniques behind its U9 Xtreme supercar, which recently set a production EV lap record at Germany’s Nürburgring Nordschleife.

According to an exclusive report by Car News China, the U9X completed the 20.8-kilometer track in 6:59.157, becoming the first series-produced battery electric vehicle (BEV) to achieve a sub-seven-minute lap on the circuit. According to the Yangwang Research Institute, part of the BYD Auto Engineering Research Institute, the result reflects a multi-year investment into advanced body engineering using aerospace-derived materials and processes.

Custom topology supports extreme speeds

The U9X chassis is built using a proprietary high-strength aluminum alloy developed specifically for the project. The material, adapted from aerospace lightweighting research, reportedly delivers three times the yield strength of conventional cast aluminum while maintaining overall balance in rigidity and safety.

Engineers employed a design method called multidimensional surface parametric modeling to navigate the complexity of curved geometries. The resulting structure, known as the Printing HyperCell, integrates honeycomb-like internal cavities and ribs, which Yangwang claims increases torsional stiffness by more than 200% compared to traditional solid equivalents of the same weight.

Laser selective melting technology enables sub-millimeter precision, with key installation surfaces manufactured to within 0.1 millimeter tolerance—comparable to specifications used in aircraft engine assemblies. To offset thermal deformation during the printing of thin-walled components, the engineering team applied dynamic process compensation algorithms.

Additive vehicle manufacturing is already here

Yangwang reports that the combination of materials science, topology optimization, and high-precision manufacturing allows the U9X body to maintain aerodynamic and structural integrity at speeds up to 400 kilometers per hour.

The 3D printed structure recently received top jury honors at the European Car Body Conference, marking the first time a Chinese-branded project has earned recognition at the event. The award underscores the feasibility of adapting aerospace engineering methodologies to automotive production and highlights growing interest in additive manufacturing for future vehicle platforms.