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No expense spared: Bugatti explains how it 3D-prints exotic metal parts

Bugatti deputy design director Frank Heyl told Autoblog his team doesn't balk at using the most expensive materials available, and he meant it. The company described how it 3D-prints titanium and alloy parts to save weight. Look closely at the back end of the 304-mph Chiron Super Sport 300+ or the agile Chiron Pur Sport and you'll spot 3D-printed titanium components. They're the intricately-designed covers installed over the exhaust pipes; they stick out from the carbon fiber diffuser. Each part weighs four pounds, which makes it 2.6 pounds lighter than the one fitted to the standard Chiron. It's one of the weight-saving measures Bugatti took to create both cars. Manufacturing the part requires firing up four 400-watt lasers that stack 4,200 individual layers of metal powder on top of each other while fusing them. The part is extremely thin in places but remarkably solid thanks to what Bugatti refers to as a "bionic honeycomb" structure, and it's capable of withstanding temperatures of up to 1,200 degrees Fahrenheit. That might sound like overkill, but keep in mind the cover is on the receiving end of a 1,500-horsepower, 16-cylinder engine. The exhaust system gets really hot, really quickly under heavy acceleration. Bugatti began using 3D printing in 2018, and now the Chiron Sport, the Divo, the one-off La Voiture Noire, and the Centodieci all use components made with 3D-printed metals. The part that covers the Sport's four visible exhaust tips (there are six in total) is notably manufactured using Inconel 718, a nickel-chrome alloy whose audial resemblance to a mid-engined model is purely coincidental; it's not a blend of molten Porsches. It's a material normally used in gas turbines, the blades attached to airplane engines, space ships, and even rocket engines. Making the cover takes several days. Engineers scan every part they produce with a computer tomograph to detect air bubbles that can get trapped between the layers during the printing process. If there are none, the part is blasted with a material named corundum, painted, and sent to the Bugatti Atelier in Molsheim, France, where it's checked yet again before it's installed on the car. Few exhaust tips have such a fascinating story to tell. "The advantage of the 3D printing process lies in the geometric shapes that are possible," said Nils Weimann, Bugatti's head of body development.

Bugatti to replace outgoing Veyron with new Chiron

With around a dozen new units left up for grabs, the Bugatti Veyron is near the end of its production cycle. For its part, Bugatti is planning to replace it with another hypercar, and while it's surely already under development, lips in Molsheim remain tightly sealed until the last Veyron leaves the factory. In the meantime, though, we've got some clues to go by. And the latest comes courtesy of Car and Driver.
According to emerging intel, the Veyron's successor will wear the name Chiron. The name belongs not only a mythological Greek centaur but also to one of the most successful racing drivers of Bugatti's heyday - certainly one of the most prominent not to have been featured in the company's recent Legend series. His name did, however, adorn the Bugatti 18/3 Chiron (pictured above), one of the concepts from the late 90s that paved the way for the Veyron's arrival.
Aside from the name, there are precious few details to go by, but we can expect it to be powered by the company's 8.0-liter W16 engine, unnaturally aspirated and with a likely hybrid boost. Look for even more staggering performance than the Veyron's, with nimbler handling thanks to lighter-weight construction.

Bugatti files for Rembrandt patent

Though increasingly uncommon today, back in the day every automaker had a hood ornament. Bugatti's was an elephant standing up on its hind legs with its trunk extended into the sky. It capped the nose on the famous Bugatti Type 41 Royale, and it was designed by Rembrandt.
No, not the famous Dutch artist, but Rembrandt Bugatti - the younger brother of carmaker Ettore Bugatti who was named after the painter.
So why do we mention this, you ask? Because one of our readers just alerted us to a patent application with the European Union's Office for Hamonization in the Internal Market. It was filed by Audi's intellectual property office on behalf of its sister company and encompasses the name Rembrandt Bugatti.