McLaren and Divergent to Create 3D Printed Parts for the McLaren W1

Last year, McLaren announced a strategic collaboration with California-based manufacturer Divergent Technologies (Divergent3D) in a significant step forward towards the application of additive manufacturing in the supercar sector. The new McLaren W1, which incorporates technology inspired by Formula 1, is at the heart of this collaboration. The aim was to design the most optimized suspension system possible and integrate it into the carbon fiber monocoque. To achieve this, key components such as the front upper wishbone, the aeroform lower wishbone and the front strut were produced for the supercar of the future using 3D printing.

The W1 is a hybrid supercar inspired by McLaren’s legendary F1 and P1 models. Its engine combines a twin-turbo V8 with hybrid assistance, develops 1,275 HP, and reaches a top speed of 350 km/h (217 mph). With a dry weight of 1,399 kg, the use of ultra-lightweight and highly resistant 3D-printed chassis parts is closely linked to the car’s concept. According to the manufacturer, it draws on 50 years of expertise in motor racing and embodies the spirit behind McLaren and its F1 mindset.

Several parts of the “supercar of the future” were 3D printed.

An Overview of Divergent’s 3D Printing Technology

Divergent’s core technology is the Divergent Adaptive Production System (DAPS), a comprehensive digital solution for manufacturing that combines AI-assisted generative design, laser powder bed fusion and robotic assembly technology. This platform enables McLaren to manufacture extremely complex parts without the traditional tooling costs, while significantly accelerating design cycles. The manufacturer thus creates parts that are optimized in terms of rigidity, durability and aerodynamics.