How LEGACY MOTOR CLUB Redefines NASCAR Production with Large-Format AM

In the high-stakes world of NASCAR, where championships are won in the margins of milliseconds, the “speed to track” is as critical as the speed on it. LEGACY MOTOR CLUB, the team co-owned by legends Jimmie Johnson and Richard Petty, has been integrating industrial 3D printing into the heart of their race shop. By partnering with BigRep and deploying two STUDIO systems, LEGACY MOTOR CLUB has transitioned from a reliance on external vendors to a high-cadence, in-house production model. This helps the team go from having raw components, to a complete car, in roughly four weeks.

LEGACY MOTOR CLUB competes under the Toyota Racing banner. It has three Toyota Camry XSE race cars built for the NASCAR Cup Series: the No. 43 driven by Erik Jones, the No. 42 piloted by John Hunter Nemechek, and the No. 84, raced part-time by Jimmie Johnson.

Breaking the Outsourcing Cycle

Before adopting large-format additive manufacturing, LEGACY MOTOR CLUB faced long lead times. Prototyping a single aerodynamic component or specialized fixture often meant waiting two to three weeks for an external supplier. In an interview with BigRep, Steven Sander, the Director of Aerodynamics at LEGACY MOTOR CLUB, said, “Our cars are rebuilt weekly, and the performance margins are extremely small, so we need to prototype, iterate, and produce parts very quickly. That is where having in-house additive manufacturing becomes a real advantage.”