Additive ManufacturingAutomotive

New Lamborghini Huracán STO features 3D printed aerodynamics key

Whenever a new Lamborghini is launched we scramble to find out which parts of it are 3D printed. Thanks to the deal made with Carbon, it’s usually quite a few. The fact that Bugatti CEO Stephan Winkelmann – a strong supporter of the use of metal AM – is now taking over the President role at Lamborghini as well (both are part of the Volkswagen Group) probably means we will see more metal printed parts in upcoming Lambos as well. In the new Lamborghini Huracán STO (Super Trofeo Omologato), 3D printing innovation focuses on a 3D printed key.

We don’t know much about the 3D printed key other than it’s clearly 3D printed and that it’s shape seems to indicate that serial version (well, the other dozen that Lamborghini is going to “serially” manufacture) will be 3D printed as well. The layer lines

The key is used to regulate the supercar’s comprehensive aerodynamic solutions, inspired by Squadra Corse race cars, to maximize aerodynamic performance. Specifically, it seems to be used to activate the system that modifies the load on the rear wing.

Lamborghini Huracán STO
The 3D printed key goes in here: “carico ala” means “wing load”.

The front bonnet, fenders and the front bumper of the Lamborghini Huracán STO are comprised of one single component: the ‘cofango’ created by Lamborghini engineers combines the ‘cofano’ (hood) and ‘parafango’ (fender) including the front bumper, inspired by the Lamborghini Miura and more recent Sesto Elemento. It is not only lightweight, but also a timesaving access feature in motorsports.

New air ducts on the front bonnet increase the airflow through the central radiator to improve engine cooling as well as helping generate downforce. The cofango also incorporates a new front splitter, directing airflow to the newly designed underbody of the car and to the rear diffuser.

The cofango is shaped to push the airflow on top of the front fenders, which incorporate louvers to maximize airflow exiting from the wheelhouse, reducing pressure inside and increasing the front downforce. The side profile of the cofango directs airflow around the front wheels, reducing drag.

Lamborghini Huracán STO
The key is used to regulate the aerodynamic load on this.

A new rear fender derived from the Super Trofeo EVO achieves both reduction of the front area of the car and consequently the drag, while increasing rear downforce and the car’s overall aerodynamic efficiency. A NACA air intake integrated into the STO’s rear fender serves as an engine air intake, with the shortened duct allowing a 30% decrease in static pressure losses.

The revised rear hood design features an integrated air scoop to improve air-cooling at the rear underhood. Dedicated air deflectors, integrated in the rear bonnet’s frame, manage the significant incoming airflow from the snorkel according to the temperature regulation needs of the engine and exhaust outlet.

An integrated ‘shark fin’ on the rear bonnet improves the dynamic abilities of the STO, particularly when cornering: in such conditions the incoming airflow has a yaw angle, and the different pressure levels generated by the two sides of the fin create a positive effect on yaw stability. The fin also helps straighten airflow onto the wing, increasing wing efficiency during cornering.

Lamborghini Huracán STO
This is what you get. Just gorgeous.

A manual, easily adjusted aero set-up of the new rear wing optimizes aerodynamic balance and drag resistance according to track characteristics. A single slotted wing with double airfoil allows the front part of the airfoil to rotate into three positions to enhance rear downforce. By reducing the gap between the front and rear airfoil, compression is increased on the upper side, upping the suction intensity and extension on the bottom of the front airfoil. The aero balance of the car can thus fluctuate by 13%, adapting the STO to different driving styles and conditions.

New front brake cooling ducts are dedicated to cooling the discs and calipers of the new CCM-R brakes, working in conjunction with the cofango air-louvers that dispel hot air from the front wheelhouses. Additional air intakes including on the underbody, and optimized nolders, are located at the rear.

The Huracán STO achieves the highest level of downforce in its class with the best aero balance for a rear-wheel drive car, with delivery of a superior aerodynamic load a key factor in its enhanced cornering performance. Overall airflow efficiency is improved by 37% and a significant downforce increase of 53% is reached over the Huracán Performante.

Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based 3dpbm. Today the company publishes the leading news and insights websites 3D Printing Media Network and Replicatore, as well as 3D Printing Business Directory, the largest global directory of companies in the additive manufacturing industry.

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