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New Bugatti Tourbillon to integrate Divergent’s 3D printed parts

Divergent Adaptive Production System (DAPS) used to design, engineer, additively manufacture, and assemble chassis and suspension components

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In 2004, the reborn Bugatti brand transformed the world of automotive performance and luxury with a 1,001 hp hypersports car: the Veyron. The first road car with more than 1,000 hp was succeeded in 2016 by another ambitious engineering feat that reset all expectations of performance, the world’s first 1,500 hp car: the Chiron. In between, in 2013, a startup called Divergent invented an entirely new way to make hypercars, implementing metal additive manufacturing for the entire chassis and many other parts. Now, 20 years after Bugatti invented the hypersports car, it redefines the concept completely with an entirely new powertrain and platform. This is the Bugatti Tourbillon from Bugatti Rimac and it features DAPS additive manufacturing technology from Divergent for the hypercar’s chassis and suspension.

Mate Rimac, CEO of Bugatti Rimac, said: “The development of the Bugatti Tourbillon was guided at every step by the 115 years of Bugatti history and the words of Ettore Bugatti himself. His mantras ‘if comparable it is no longer Bugatti’ and ‘Nothing is too beautiful’ was a guiding path for me personally, as well as the design and engineering teams looking to create the next exciting era in the Bugatti hyper sports car story.”

The Tourbillon is designed around an entirely new chassis and body structure. The structure is made from a next-generation T800 carbon composite, which incorporates several weight-saving innovations, such as integrating the battery as a structural part of the monocoque and an unprecedented crash composite rear diffuser, inspired by top-level motorsport. The front composite air ducts that flow through the front of the car are also integral to the structure, ensuring that each and every part of the rigid, lightweight structure is optimized. For example, the front and rear frames exhibit low-pressure thin wall aluminum casting and 3D printed structural braces, contributing to a structure that is significantly lighter and stiffer than its predecessor!

The completely new chassis integrates multi-link suspension front and rear, forged from aluminum, moving on from the double wishbone steel construction found in the Chiron. By opting for a new organic-designed suspension arm and upright, 3D printed in aluminum via DAPS, Bugatti Rimac engineers have saved 45% in suspension weight compared with the Chiron. The rear also features an AI-developed 3D printed hollow airfoil arm to enhance vehicle dynamics and aerodynamic performance.

Bugatti Tourbillon from Bugatti Rimac to integrate Divergent's 3D printed parts via Divergent Adaptive Production System (DAPS)

The brakes are equally advanced, featuring the ultimate carboceramic technology. A bespoke brake-by-wire system is introduced, fully integrated with the moveable pedal box, and blended seamlessly through an integrated vehicle non-linear controller developed by Bugatti to the hybrid powertrain. Michelin Pilot Cup Sport 2 tires – 285/35 R20 at the front and 345/30 R21 at the rear – are a bespoke development for the Tourbillon.

Within the new chassis, the new ultra-compact and lightweight front e-axle with dual independent motors, including the dual-inverter, fits within the same package space that was available in Chiron, adding more complexity without requiring more space. Designers and engineers also freed up more storage space and a larger luggage component, as part of the clean-sheet chassis and bodyshell design, allowing owners to fit a set of bespoke Bugatti Tourbillon luggage.

“We are pleased to provide structures for the Tourbillon that complement the aesthetic beauty that the world has come to expect from Bugatti,” said Lukas Czinger, President and Chief Operating Officer of Divergent. “Today’s announcement demonstrates Bugatti’s commitment to integrating next-generation technology into its performance vehicles.”

Bugatti Rimac will utilize the Divergent Adaptive Production System (DAPS) to design, engineer, additively manufacture, and assemble chassis and suspension components for Bugatti’s upcoming hypercar, the Tourbillon.

Divergent’s digital, end-to-end approach to vehicle design and manufacturing enables Bugatti to unlock more efficient geometries for the vehicle chassis, dramatically reducing the weight of the vehicle and improving performance. This collaboration is a testament to Bugatti’s commitment to delivering superior driving dynamics and an exceptional driving experience.

Mate Rimac, CEO of Bugatti Rimac further commented, “We are excited to announce this partnership after working closely together for the past 18 months. It is clear that Divergent is the industry leader in digital engineering and additive manufacturing. These optimized chassis components find their perfect home in our most advanced vehicle to date.”

“We look back through Bugatti history at the creations of Ettore and Jean and you can immediately see that they refused to compromise, Mate Rimac, Bugatti CEO, went on. “The amount of patents Ettore had to his name was incredible because he didn’t ever want the simplest solution, he always wanted the best solution, even if it didn’t exist yet. He’d go away and he’d build it, test it and refine it until it was perfect. And then he’d make it beautiful. It is why the cars are so revered today, and it is the driving force behind everything we have done with Tourbillon.

“So yes, it is crazy to build a new V16 engine, to integrate with a new battery pack and electric motors and to have a real Swiss-made watchmaker instrument cluster and 3D printed suspension parts and a Crystal Glass center console. But it is what Ettore would have done, and it is what makes a Bugatti incomparable and timeless. Without that kind of ambition, you might create a great hyper sports car, but you wouldn’t create an icon Pour l’éternité’.

The Bugatti Tourbillon now enters its testing phase, with prototypes already on the road in anticipation for customer deliveries in 2026. A total of 250 examples will be built, with a starting price of 3.8 million EUR net. Hand assembly will take place at the Bugatti Atelier in Molsheim, following the final W16-powered Bugatti models, Bolide² and W16 Mistral³.

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