Additive ManufacturingAutomotive AM

Czinger shows off first topology optimized 3D printed gearbox

Created in collaboration with Xtract and ready for production

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Czinger Vehicles has introduced a topology-optimized, fully 3D printed gearbox that is yet another world-first innovation – and when Czinger says it’s a first it really is a first, usually far ahead of its time. The company partnered with Xtrac, a global leader in Motorsport & High-Performance Automotive (HPA) gearbox production, to pioneer the first topology-optimized and additively manufactured gearbox case.

The production of the gearbox uses a unique printing process and proprietary aluminum alloy, resulting in significant mass savings, outstanding structural performance, production quality, and efficient printing times. Furthermore, this approach eliminates the need for tooling, achieving a substantial reduction in development time, and the ability to make real-time design improvements. The gearbox is an early example of the company applying this advanced technology to powertrain systems and further enables the 21C’s industry-leading performance. Most importantly, while this is a prototype, it is also the same exact product that would go in production.

“We are proud to team Czinger’s world-class engineers with those at Xtrac; together, we have developed an incredible, industry first, gearbox that is truly at the pinnacle of performance. We can’t wait to shatter more track records as we utilize this system in the 21C,” said Czinger Co-Founder and SVP Operations Lukas Czinger.

Czinger shows off first topology optimized 3D printed gearbox, created in collaboration with Xtract and ready for production

Xtrac maintains a longstanding legacy of excellence in gearbox manufacturing, designing and manufacturing top-line motorsport transmissions and differentials since 1984 and in those 30-plus years, over 1,200 unique gearbox designs have been produced. The brand consistently turns out top-line gearboxes used in top-level professional motorsport globally. Partnering with Xtrac to engineer and develop the 21C’s 3D-printed gearbox is a testament to Czinger’s strong commitment to performance.

The cutting-edge automated 7 speed semi sequential gearbox boasts leading performance specifications, starting with the first 48V electrically actuated twin barrel system, resulting in the fastest automated single-clutch synchromesh gearbox in existence. Dual barrel gear actuation allows for seamless EV to Rear Drive blending for smooth city driving. Sub 100ms shifts combined with blending of front axle EV power allows for seamless shifts for high-performance driving. It also has the highest torque transmitted per mass of gearcase for any road legal vehicle.

“What our Xtrac engineers have accomplished in tandem with Czinger and Divergent is groundbreaking. Xtrac is pleased to be at the forefront of cutting-edge gearbox manufacturing by creating these 3D printed casings. It has been extremely interesting and very stimulating for our engineers working closely together to bring this cutting-edge innovation to life,” commented Xtrac CEO Adrian Moore

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Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based VoxelMatters. Today the company publishes the leading news and insights websites VoxelMatters.com and Replicatore.it, as well as VoxelMatters Directory, the largest global directory of companies in the additive manufacturing industry.

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