April 18, 2014

Swedish automaker Koenigsegg is celebrating its 20th birthday this year. For the occasion, the company has unveiled the Agera One:1, the hypercar it says will be "world's first megacar". It is the first production car that offers a 1:1 power to weight ratio — it weighs 1340kg and produces 1322bhp (1340 metric horsepower). That's even more than the 1184bhp Bugatti Veyron Super Sport – the world's fastest production car according to Guinness World Records. Five units of the One:1 are thought to have been produced, retailing for around $2 million (€1.45 million).

In the video below, Koenigsegg CEO and founder Christian von Koenigsegg explains how the company takes advantage of 3D scanning and 3D Printing technology to ensure its cars are lightweight and as advanced as possible.

Koenigsegg explains that designers use 3D laser scanning technology to scan the shape of a prototype mold of car seat, and then they can create skin of the seat and perfect the surfaces and shapes in the computer. Many of the parts were first 3D printed in 1:1 scale, allowing the company to explore the shape and test the feel of those components before using them in the real car. And they're also producing some parts for the production cars in 3D printed ABS and titanium. With 3D printing, engineers are able to make changes freely to speed up car design development and save design cost.

The new Agera One:1 features 3D-printed variable turbo housings for improved response and low-end torque. Koenigsegg 3D printed titanium exhaust end piece that saves 14 ounces (400 grams / 0.88 pounds) of weight. Another weight saving measure includes a 20-percent lighter carbon fiber chassis made with new high modulus fibers. Koenigsegg says for low volumes and light-weight components, 3D printing is more cost-effective than tooling and capable of creating all complex shapes.

Koenigsegg uses a hybrid approach where they 3D print an initial prototype, modify it by hand using traditional methods, then 3D scan that modified part to create a new 3D model. Koenigsegg feels this is where the future of the industry is going.


Posted in 3D Printing Applications

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