Metal additive manufacturing technology is accelerating industrial development in the automotive sector, as shown by the repeated success of the Bugatti sports car brand in achieving consistent function integration and significant performance optimization of components.
Sparks fly during the dynamic bench testing of a Bugatti brake caliper, the volumetrically largest functional titanium component built with selective laser melting to be tested.
The caliper test showed that a tensile strength of 1,250 N/mm2 and a material density over 99.7% was achieved.
The component was manufactured in the aerospace alloy Ti6Al4V with Fraunhofer IAPT (formerly Laser Zentrum Nord) and Bionic Production AG on an SLM®500 featuring four 400 W lasers.
Bugatti utilizes selective laser melting not only for lightweight but also within the functional scope of its vehicles. The active spoiler bracket, manufactured on an SLM®500 with Fraunhofer IAPT (formerly Laser Zentrum Nord), represents this combination, aiding the 1,500hp vehicle to reach speeds of 400 km/h in just 32.6 s and bringing it back to a stop in just 9 s. The active rear spoiler can be adjusted in height and angle, supporting the sophisticated aerodynamics required.