335bhp Cupra Leon Competicion adopts 3D printed components

In order to streamline the development process, Cupra has opted for 3D-printed components in its track-only Leon Competicion

Some might believe the usefulness of 3D printing is limited to the creation of poorly finished plastic trinkets, but through advancements in technology, the automotive industry is now using it in a number of more interesting applications. The latest example can be found in the new Cupra Leon Competicion, a track-only racer destined for the World Touring Car Championship. 

As with any car of this kind, power has been lifted from road car figures, bringing output from its 2.0-litre turbocharged 4cyl to 335bhp and 302lb ft of torque, enough for a swift 4.5sec 0-62mph time and 162mph top speed.

> New 2020 Cupra Leon revealed ­– Cupra hits back with hot hatch and estate

Elsewhere, chassis tweaks sharpen the Leon for on-track performance, with adjustable suspension, uprated brakes and an FIA-approved roll cage and seat all featuring. As you might have gathered, plenty of aerodynamic changes have also been made, ranging from the aggressive new front splitter and bonnet, to that rather significant rear wing. 

What sets this model apart from the rest, however, is the use of 3D printed components throughout. Using multi-jet fusion technology, Cupra and HP collaborated on the creation of 3D printed door mirrors, air intakes, bonnet vents and other componentry. All the printed parts stood up to wind tunnel testing at speeds of 180mph, proving they can cope with the toils of high speed track sessions. 

The use of the technology allows for a more streamlined development process, letting engineers print multiple new components in a short period to be tested in one session. The resin used for the printing is also said to be much lighter than the material ordinarily used for such applications, therefore reducing weight and increasing efficiency. 

Xavi Serra, head of technical development at CUPRA Racing, said: ‘The main goal is to have a lot of parts in a short time. We can quickly test a wide variety of designs and furthermore, this technology enables us to react swiftly to any changes in the design process.’

Not only is the Leon Competicion one of the first models to feature 3D printing, but it’s also the very first touring car to be available to order online. Pricing is yet to be announced, however order books are open now. 

Recommended

Toyota GR Yaris 2021 review - a true homologation superstar
2021 Toyota GR Yaris black - header
Toyota Yaris

Toyota GR Yaris 2021 review - a true homologation superstar

Toyota’s new road-going rally special is a great drivers’ car of the type we worried we’d never see again. It’s a little gem.
26 Mar 2021
Hyundai i20 N 2021 review – hot supermini zeros in on the Ford Fiesta ST
Hyundai i20 N - front tracking
Hyundai i20

Hyundai i20 N 2021 review – hot supermini zeros in on the Ford Fiesta ST

An inspiring new hot hatch from Hyundai N. Agile, and with a limited slip differential that offers superb mid-corner traction, it’s a formidable Fiest…
26 Mar 2021
2021 Audi RS3 nears production – will it finally match Mercedes-AMG A45 S?
Audi RS3 mule 2021 - front quarter
Audi RS3

2021 Audi RS3 nears production – will it finally match Mercedes-AMG A45 S?

Audi Sport is putting the final touches on its new RS3 hot hatch and saloon
24 Mar 2021
Best hot hatches 2021
best hot hatchbacks 2021
Hot hatchbacks

Best hot hatches 2021

It’s a simple notion, but the hot hatchback can be as exciting as any supercar, and just as enticing
11 Mar 2021

Most Popular

Jaguar XJ41 – Dead on arrival
Jaguar XJ41
Jaguar

Jaguar XJ41 – Dead on arrival

The blighted ’80s ‘F-type’, the demise of which led to the creation of the Jaguar XK8 and launched a new era for Aston Martin
8 Apr 2021
New Mercedes CLS revealed – four-door coupe gets a refresh
2021 Mercedes CLS53 – front static
Mercedes CLS

New Mercedes CLS revealed – four-door coupe gets a refresh

Merc’s sleek CLS has received a few choice updates and a Panamericana grille for 2022
7 Apr 2021
BMW M4 mule with aero mods caught in testing
BMW M4 CS prototype 2021 - rear
BMW M4 coupe

BMW M4 mule with aero mods caught in testing

Could a BMW M4 CS, or perhaps even a new CSL, already be in the works?
12 Apr 2021