The piston was made for its Chaos ultracar using an XJet 3D printer.
According to XJet, the Chaos car, which is currently in development, can reach speeds of over 500 kph with acceleration from 0 to 100 kph in 1.55 seconds.
The piston was made using a propriety design for additive manufacturing (AM) called ‘anadiaplasi’ in which, according to SPA, a component takes its shape based on the forces acting on it. Material is therefore minimised where it doesn’t support performance and added where reinforcement is needed, improving weight while maintaining the strength and temperature resistance of the part.
The company selected XJet’s Alumina ceramic material due to its improved strength, hardness, light weight, and almost total resistance to thermal expansion, XJet said.
“Ceramic offers many advantages compared to other materials,” said Spyros Panopolous, founder of SPA. “Harder and stiffer than steel, more resistant to heat and corrosion than metals or polymers and weighing significantly less than most metals and alloys. XJet’s alumina parts will withstand the high temperatures expected to develop within the combustion chamber as well as on the fast-moving parts.
“I believe this is the first-time ceramic AM is being used in motorsport and I feel privileged to take that pioneering step.”
In total, around 78% of the ultracar body will be 3D printed as well as other elements such as the engine block, camshaft and intake valves.
