Case study · Automotive & motorsport

How vapor smoothing helps 3D-printed rally car parts perform in extreme racing conditions

Rally racing pushes every component of a car to its limits. ABConcept set out to prove that 3D-printed parts could thrive there, equipping its Zephyr rally car with PA12 components printed on HP Multi Jet Fusion and finished with PostPro vapor smoothing.

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ABConcept rally car throwing up a plume of dust on a desert stage
PhotoThe ABConcept Zephyr rally car at the Rallye du Maroc.
Customer
ABConcept
Industry
Automotive & motorsport
Application
Rally car components
Printing
HP Multi Jet Fusion
Material
PA12
Finishing
PostPro vapor smoothing
Published

Built for the stage

The Zephyr carried more than 100 PA12 components printed with HP MJF, and those parts faced more than 2,450 km of intense terrain at the Rallye du Maroc.

To meet the mechanical demands of high-speed, high-stress racing, ABConcept made PostPro vapor smoothing part of its workflow. The finishing step enhances durability, seals surfaces and improves resistance to wear, oil and debris, which makes it a key production step for motorsport applications.

The result

The combination of MJF printing and automated vapor smoothing shows how additive manufacturing can deliver strong, lightweight and reliable car components built for extreme conditions.

Results

  • 100+PA12 components on the Zephyr rally car
  • 2,450+ kmof the Rallye du Maroc

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