Ken Block's 'Hoonitruck' uses a 3D-printed intake manifold

Gymkhana 10 star Ken Block's love affair with Ford pick-ups runs deep. He learned to drive in one, did his first burn-out in one and made a 1977 Ford F-150 the star of his latest video.

The 'Hoonitruck' has the same twin-turbo 3.5-litre V6 EcoBoost engine as the Ford GT, tuned to deliver more than 900bhp, and the largest 3D metal-printed part for a working vehicle in automotive history.

The project was a global effort. Ford Performance engineers in America ran engine performance simulations and collaborated with a team of Ford research engineers based in Europe to design the part and conduct structural analysis. Working together with RWTH Aachen's Digital Additive Production Institute, in Germany, the team built an intricate aluminium intake manifold that supplies air from the turbochargers to the engine's cylinders.