Additive ManufacturingAutomotive

APWORKS additively produces the exhaust tailpipe for the brand-new Bugatti Chiron Pur Sport

The Bugatti factory – like those of just about every major automaker in Europe – is closed due to the COVID-19 pandemic, however, development and automated production is ongoing at APWORKS, one of its suppliers. The advanced manufacturing firm is additively manufacturing the extremely lightweight and highly temperature-resistant exhaust tailpipe for the latest Bugatti Chiron Pur Sport.

Bugatti is now new to the use of AM. The company has worked with SLM Solutions and Siemens on a number of parts for its gorgeous hypercars, making headlines with the brake caliper, the largest end-use automotive part ever produced with metal AM. This new and sophisticated exhaust tailpipe applied in the Bugatti Chiron Pure Sport is also produced with additive manufacturing out of Titanium. This production method gives the component very thin walls, thus helping to save weight where it really matters. Additive Manufacturing is the best-suited manufacturing method as it enables a degree of design freedom no other manufacturing method is capable of.

The exhaust tailpipe is part of the extraordinary rear design of the Chiron Pur Sport – a new aerodynamic configuration that generates more downforce while the lower weight increases agility. “By cutting the weight by 50 kilograms while simultaneously boosting the downforce and configuring an uncompromising, sporty chassis as well as suspension setup, the Chiron Pur Sport boasts incredible grip, sensational acceleration and extraordinarily accurate handling. It’s the most uncompromising yet agile Bugatti of recent times,” explained Stephan Winkelmann, President of Bugatti.

The lightweight and temperature-resistant 3D printed exhaust tailpipe produced by APWORKS. Image source: Bugatti

The low mass of the tailpipe contributes to the new aerodynamic configuration of the hyper sports car dedicated to driving on extremely winding roads. This new Chiron is geared even more towards agility and dynamic cornering. “We focused particularly on the agility of the Chiron Pur Sport. The vehicle generates more downforce at the rear axle while the large, front splitter, air inlets, wheel-arch vents featuring optimized air outlets and a reduced vehicle height strike a clean balance at the front” said Frank Heyl, Head of Exterior Design and Deputy Head Designer at Bugatti.

The exhaust tailpipe is additionally highly temperature resistant due to the production out of titanium, as this material combines high strength and good heat resistance. This is a prime example of an optimized high-performance part enabled by additive manufacturing fulfilling the highest quality standards an receiving the road homologation.

“We are proud to be part of this impressive new sports car development of Bugatti. It is the first visible metal 3D printed part receiving the road homologation. We could only realize this innovative tailpipe by pushing the additive manufacturing technology to the limit. The smallest wall thickness of below 0.5mm enables the extremely lightweight design.” commented Joachim Zettler Managing Director of APWORKS.


Davide Sher

Since 2002, I have built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, I spent 12 years in the United States, where I received my Bachelor of Arts undergraduate degree. As a journalist covering the tech industry - especially the videogame industry - for over 10 years, I began covering the AM industry specifically in 2013, as blogger. In 2016 I co-founded London-based 3D Printing Business Media Ltd. (now 3dpbm) which operates in marketing, editorial, and market analysis & consultancy services for the additive manufacturing industry. 3dpbm publishes 3D Printing Business Directory, the largest global directory of companies related to 3DP, and leading news and insights websites 3D Printing Media Network and Replicatore. I am also a Senior Analyst for leading US-based firm SmarTech Analysis focusing on the additive manufacturing industry and relative vertical markets.

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