Project Chaos: when an ultracar meets 3D printing

Spyros Panopoulos is a Greek racing car enthusiast who has given his name to his company: he recently unveiled the new project he has been working on for the past two years. Project Chaos is a ultracar with very high performance that should be fully revealed in March 2021. However, some details were given, including the fact that it incorporates 3D printed elements such as pistons and connecting rods, and that it can reach 500 km/h. With its 3,000 horsepower, Project Chaos lives up to its name and should make a lot of noise in the automotive industry.

When it comes to additive manufacturing, the automotive industry, in particular luxury cars, is one of the most interested markets because it offers high levels of customization as well as performance gains. Consumers are looking for tailor-made solutions that can differentiate them from their others and 3D printing can respond quickly to this demand. One example is the MINI manufacturer, which has launched its personalisation service to design side decorations, door frame lighting and customised inserts. In the case of Project Chaos, additive manufacturing has above all made it possible to produce highly complex parts and reduce weight and lead times.

Spyros Panopoulos and the ultracar

Project Chaos: an ultracar that integrates 3D printing

Two versions of the car should be available, both based on a 4-litre V10 engine with 20 injectors and 40 valves. One of them would incorporate 3D printed titanium pistons and connecting rods, running at a speed of 11,000 rpm. It is not known exactly which metal 3D printing process was used, but the photos published by Spyros show a directed energy deposition (DED) technology. The second is expected to have carbon fibre connecting rods and pistons 3D printed with a ceramic material. This material is said to be very strong, light and hard – Spyros Panopoulos explains that it used to be used on space shuttles.