Bugatti Bolide: a light and fast vehicle thanks to 3D Printing

The French carmaker Bugatti has probably imagined the lightest, fastest and most aggressive vehicle in its range. Called Bolide, this sports car is an assortment of new technologies, relying, in particular, on additive manufacturing to reduce the weight of its components. It weighs about 1,240kg (2733.7lbs) compared to the 1,996kg (4400.4lbs) of its flagship Chiron model, while achieving a weight-to-power ratio of 0.67. For now, the hypercar is only an experimental study, but it could very well go beyond the project stage by demonstrating all the benefits of automotive additive manufacturing.

In January 2018, the French brand revealed a first brake caliper printed in 3D metal, more precisely titanium. This first in the automotive sector reduced the total weight of the part by 2kg (4.4lbs), a 40% reduction. One year later, Bugatti renewed its confidence in 3D printing technologies by relying on the SLM Solutions process to build not only a spoiler support but also an engine mount. Henrik Hoppe, a doctoral student at Bugatti, explains: “Through the process known as selective laser melting, commonly known as 3D printing, new, hollow, ultracomplex components that are stiffened from the inside can be produced which are very lightweight and yet extremely rigid and strong. We are using these advantages for a growing number of components in our hyper-sporty cars.”

One of the 3D printed pieces on the Bugatti Bolide (photo credits: Bugatti)

Bugatti Bolide, a compilation of new technologies

Bugatti has drawn on its experience in additive manufacturing to design this new sports car, which incorporates numerous 3D printed parts, with the ultimate goal of reducing weight while maintaining high rigidity. Looking at the additively designed components, we can cite push rods weighing only 100 grams, which have an internal support arch that provides sufficient strength to support loads of up to 3.5 tons. It would appear that topology optimization methods were used in order to obtain a structure that could withstand pressures mainly concentrated in the center of the part.