Sparks fly during the dynamic bench testing of a Bugatti brake caliper, the volumetrically largest functional titanium component built with selective laser melting to be tested.

"Proof that additively produced metal components can cope with extreme strength, stiffness and temperature requirements at speeds of over 375 km/h with a braking force of 1.35g and brake disc temperatures up to 1,100°C," says Frank Götzke, Head of New Technologies at Bugatti. The caliper test showed that a tensile strength of 1,250 N/mm2 and a material density over 99.7% was achieved.

Bugatti utilizes selective laser melting not only for lightweighting, but also within­­ ­the functional scope of its vehicles. “We always strive for absolute perfection, stylistic as well as technical, as well as considering the perfect synergy of both elements – the tradition of Ettore Bugatti we uphold,” Götzke stated. The active spoiler bracket, manufactured on an SLM®500 with Fraunhofer IAPT (formerly Laser Zentrum Nord), represents this combination, aiding the 1,500hp vehicle to reach speeds of 400 km/h in just 32.6 seconds and bringing it back to a stop in just nine seconds. The active rear spoiler can be adjusted in height and angle, supporting the sophisticated aerodynamics required.

The component was manufactured in the aerospace alloy Ti6AL4V with Fraunhofer IAPT (formerly Laser Zentrum Nord) and Bionic Production AG on an SLM®500 featuring four 400W lasers.

 

 

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