Cupra uses 3D printing for the Leon Competicion

Cupra's team of innovative engineers is transforming the way vehicles are developed by printing car parts by using state-of-the-art multi-jet fusion technology to fashion parts in a fast and efficient way.

For the new Leon Competicion racing car, engineers at Cupra have 3D printed the model's door mirrors, air intakes and cooling intakes.

This technique enables Cupra to reduce the vehicle's fuel consumption while also increasing stability as well as speed and safety, all vital in both motorsport and road car applications.

The process of printing a mirror can take around 20 hours, but Cupra can print six at a time, giving the team the ability to create different designs simultaneously. This means Cupra can quickly test the varying prototypes in a wind tunnel to find out which is best for aerodynamics.

When taken to this controlled environment, the printed parts are fitted to the car and face winds of more than 290km/h, while sensors study the impact on individual surfaces.

The car's resistance data is displayed on a screen where engineers and designers compare the results for the different printed parts.

As the smallest margins can make the difference in motorsport, it is crucial the 3D printed parts play their part in reducing fuel consumption while also increasing stability, speed and safety.

The final development of the 3D printed parts was on a racing circuit, with Cupra testing the Leon Competicion on the Portimao track in Portugal. So far, Cupra has been printing parts for its Leon Competicion, its 290km/h, 335bhp 2.0-litre touring car inspired by the new Seat Leon family hatchback, and the e-Racer, an electric touring car that does zero to 100km/h in 3.2 seconds.