Additive ManufacturingAutomotive AM

Watch a 3D printed brake caliper being put to the test

It was produced by Bugatti using SLM Solutions technology

Stay up to date with everything that is happening in the wonderful world of AM via our LinkedIn community.

Sparks flew as Bugatti tested its generatively designed 3D printed brake caliper, additively manufactured with SLM Solutions technology. Volumetrically this part is the largest functional titanium component built with SLM technology.

The 3D printed metal part can cope with extreme strength, stiffness and temperature requirements at customers’ required high speeds. Caliper test showed a tensile strength of 1,250 n/mm² and material density over 99.7%. The part was manufactured with Fraunhofer IAPT and Bionic Production Ag.

“As our performance data are often at the physical limits, we are especially demanding, this is why Bugatti always goes at least one step further than other manufacturers in the development of technical solutions.” Frank Götzke, Head of New Technologies in the Technical Development Department of Bugatti Automobiles S.A.S.

In 2018, for the first time, Bugatti developers succeeded in designing a brake caliper that could be produced by 3D printing in titanium. This new milestone in the development of 3D printing was reached in cooperation with Laser Zentrum Nord of Hamburg, an institute that has formed part of the Fraunhofer research organization since the beginning of the year. With this world debut, Bugatti has underlined its lighthouse function for 3D printing within the Volkswagen Group and its role as an innovation driver in the international automotive industry. Vehicle trials for the use of the 3D titanium brake caliper in series production are to start in the first half of the year.

Watch a Bugatti generatively designed titanium 3D printed brake caliper, produced using SLM Solutions technology, put to the test
Watch a 3D printed brake caliper being put to the test, produced by Bugatti using SLM Solutions technology

With the newly developed titanium brake caliper from the 3D printer, Bugatti broke new ground. The Ti6AI4V alloy is mainly used in the aerospace industry, for example for highly stressed undercarriage and wing components or in aircraft and rocket engines. The material offers considerably higher performance than aluminum. For example, even as a 3D printed component, it has a tensile strength of 1,250 N/mm2. This means that a force of slightly more than 125 kg be applied to a square millimeter of this titanium alloy without the material rupturing. The new titanium brake caliper, which is 41 cm long, 21 cm wide and 13.6 cm high, weighs only 2.9 kg. In comparison with the aluminum component currently used, which weighs 4.9 kg, Bugatti could, therefore, reduce the weight of the brake caliper by about 40% at the same time as ensuring even higher strength by using the new part.

To date, this approach was not feasible because it is extremely difficult or even impossible to mill or forge components from a titanium block as is normal practice with aluminum due to the extremely high strength of the material. This problem has now been solved using an extremely high-performance 3D printer, which also opens up the possibility of generating even more complex structures that are significantly stiffer and stronger than would be possible with any conventional production process.

Research
Composites AM 2024

746 composites AM companies individually surveyed and studied. Core composites AM market generated over $785 million in 2023. Market expected to grow to $7.8 billion by 2033 at 25.8% CAGR. This new...

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.

Related Articles

Leave a Reply

Your email address will not be published. Required fields are marked *

Back to top button
Close Popup
Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

Technical Cookies
In order to use this website we use the following technically required cookies
  • PHPSESSID
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

Decline all Services
Save
Accept all Services

Newsletter

Join our 12,000+ Professional community and get weekly AM industry insights straight to your inbox. Our editor-curated newsletter equips executives, engineers, and end-users with crucial updates, helping you stay ahead.