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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.

1937 Bugatti 57SC sells for record $9.7 million at Amelia

See this car right here? It may very well be the most valuable Bugatti ever sold at auction. Any 57 would stand among the most sought-after Bugattis among collectors. But this particular 1937 Bugatti 57SC Sports Tourer features unique bodywork from British coachbuilder Vanden Plas. That may make it look more like a Jaguar or Morgan than a Bugatti, but that signature grille tells you otherwise. Chassis number 57541 was showcased at the London Motor Show and featured in some of the company's own literature, then went on to race before and after the War on our side of the Atlantic. In superlative condition, the Vanden Plas Bugatti was valued at $11-13 million heading into the Amelia Island Concours d'Elegance where it was auctioned off by Bonhams this weekend. It didn't quite get there, but at $9,735,000, the auctioneer lauds this as "the most valuable Bugatti ever sold at auction and the most valuable car ever sold at Amelia Island." That may not actually be accurate, though. Sports Car Market logs a '31 Royale that Christie's apparently sold for slightly more at $9.8 million way back in 1987, and Gooding & Company sold a '61 Ferrari 250 GT SWB California Spider for $17 million over the same weekend. One way or another, it's a lot of money, and a beautiful car that one very fortunate owner will be taking home with him (or her) from Florida this week. Check it out in the extensive image gallery above and the video clip below. Show full PR text BONHAMS' SECOND ANNUAL AMELIA ISLAND AUCTION A SMASHING SUCCESS – WORLD RECORDS MADE, SALES NEARLY DOUBLED OVER LAST YEAR, AND THE BUGATTI 57SC BECOMES THE MOST VALUABLE BUGATTI EVER SOLD AT AUCTION For immediate release – 11 March 2016 – Amelia Island, Florida – Held Thursday, March 10th at the spacious and conveniently accessible Fernandina Beach Golf Club, Bonhams' second annual Amelia Island auction was a resounding success with nearly $27.5-million achieved. With an impressively diverse and curated selection of 95 automobiles ranging from 19th century motor carriages to 21st century supercars, the handpicked assembly offered something for every taste and interest. Leading the sale was the singular 1937 Bugatti 57SC Sports Tourer by Vanden Plas. Armed with a generous amount of international buzz from the preceding weeks, this very special pre-war car had the auction tent packed to capacity with bidders and spectators. With a starting bid of $6-million, the bidding quickly rose to $8-million.

Watch Top Gear host Chris Harris sample the Bugatti Chiron's unbelievable acceleration

Update: The original video and tweet have been removed from Twitter. Yes, yes, we all know how fast the new 1,500 horsepower Bugatti Chiron is. It'll do 0-60 mph in under 2.5 seconds, 0-100 mph in just 6.5, and the top speed is 261 mph (limited). As Top Gear host Chris Harris shows here, stats and figures don't really do the car justice. The Instagram clip from the "onlychirons" account shows Harris repeatedly accelerating to triple digit speeds followed by full panic stops. The sheer glee on his face really says it all. As many enthusiasts know, Harris is no stranger to high-performance machines. He's one of the few people in the world to drive the so-called holy trinity of supercars: the Ferrari LaFerrari, the Porsche 918, and the McLaren P1. The clip here was apparently taken during the filming for the latest series of Top Gear. Look for Harris and the Chiron on an new episode in the next few weeks. Related Video: TV/Movies Bugatti Videos Top Gear chris harris Bugatti Chiron