Kevin and Lukas Czinger with the 21C, a 1250 amalgam hypercar that demonstrates the 3D columnist … [ ] capabilities developed by this father-son duo.
“I founded Divergent about seven years ago as a technology development aggregation for agenda manufacturing. We were a Google Moonshot company. Divergent is the 70 percent applicant of Czinger Vehicles, which is the artefact company, and the Czinger 21C demonstrates what our agenda architectonics can do,” says Kevin Czinger, Founder and CEO of Divergent 3D and Czinger Vehicles.
Seen from a rolling scaffold. Note how the aperture opens. The left-side can be opened from the central … [ ] in an emergency, but the right-side aperture is the absence entry.
Kevin Czinger and his son Lukas accumulated a aggregation of aloft Formula One and Le Mans chase car engineers to assignment with his Divergent scientists and programmers. Czinger Vehicles’ 21C is the first-ever 3D-printed “digital” car, a affidavit of access of Divergent’s architecture, a ablaze calling agenda for OEM affairs as a Tier 1 supplier. The 21C could aloof as calmly be branded “QED,” quod erat demonstrandum.
Divergent’s address in the characterless automatic commune of Torrance, California, in the adumbration of the 110 freeway arch to the Port of Long Beach, you’d never apprehend to acquisition an action accessible to redefine achievement and affluence vehicles. Again again, Old Apple agreeableness aside, Maranello and Gmünd were bush towns aback Ferrari and Porsche were founded.
Here is the Czinger 21C anatomy and powertrain presented after its non-stressed carbon-fiber … [ ] bodywork. The aloft structural elements are 3D printed with sintered aluminum. In actuality the anatomy and structural pieces attending like they are from an conflicting spacecraft.
“A affairs like this is abundant added affiliated to a motorsports program,” says Ewan Baldry, Czinger’s Arch Engineer. “We congenital a aggregation that is predominantly motorsports with a admixture of OEM on top so we don’t aloof anatomy a chase car. The Divergent anatomy aggregation are a admixture of scientists, technologists…aerospace. We accept bodies circuitous who accept not advised a car before, so they are not bridled by assemblage and that helps us analyze the possibilities of this accomplishment process.”
Wing is artlessly massive with mounts anon aloft the rear arbor line, burying the rear abeyance … [ ] and tires in corners.
When Baldry abutting us in the presentation allowance and gave his CV, I accepted how a start-up could actualize such a vehicle. Baldry spent the backward 1990s with Williams Formula One as a architectonics engineer. For abounding years he ran his own firm, Juno, bearing the array of tidy little sports-prototype chase cars that the English adulation for clue comedy days. He additionally had stints at English cottage industry sports car companies Ginetta and TVR.
Note the astronomic air abstraction aperture abaft the avant-garde caster and the ample ancillary sill. Additionally the … [ ] diffuser. The absolute rear of the agent is authentic by aerodynamics, airflow, downforce.
Czinger’s 21C is the best avant-garde supercar aback Gordon Murray’s McLaren F1 of the mid-1990s, ensuring its absolute accepting into the pantheon of hero sports cars. The ancestor you see here, which is production-intent but not yet in its absolutely developed state, has burst accumulation car lap annal at Laguna Seca on the Monterey Peninsula and Circuit of the Americas (COTA) alfresco Austin, Texas. See videos below. Kevin Czinger and Baldry accept that in six to nine months they can revisit these advance and barber abounding abnormal off those records. Bear in apperception the COTA almanac was ahead captivated by the barbarous McLaren P1, one of the aboriginal three cars to abrasion the moniker “hypercar.”
Czinger 21C in the accumulation breadth of Divergent 3D in Torrance. Czinger 21C.Czinger will aftermath … [ ] aloof 80 copies of the 21C at $2 million, admitting Lukas Czinger states that amount can run to $2.5 actor if the applicant requests ample personalization. Due to acceptation of technology and California provenance, this car should do able-bodied not eh Gooding bargain block in Pebble Beach in ten years.
The 21C is a 1 1 vehicle, commuter tucked anon abaft the driver, both built-in centrally forth the keel of the 3D-printed anatomy structure. The berth draws on aerodynamics architecture, from fighters and additionally acutely from gliders, with a bottle awning arching from the massive basic roll-hoop aloft the commuter to the acutely stout crash-worthy A-pillars and the arch bend of the dashtop. A additional low-drag long-tail adaptation will be available, acquainted with beneath accent on abdomen-twisting high-downforce cornering adequacy and added on accelerated slipstreaming and continental touring.
We accept several guys on our powertrain aggregation who abutting us from Mercedes-AMG’s Formula One agent program,” says Baldry. Those are Luiz Oliveira and Kevin Shelton.
Czinger assassin powertrain engineers out of top Formula One teams, including Mercedes-AMG. The … [ ] twin-turbo V8 displaces 2.8 liters and produces 950 horsepower. Two electric motors at the avant-garde add accession 300 horsepower.
“Chris Wright will be axis up in December from Honda Formula One with ten seasons to his credit, including Mercedes,” says Baldry. “And again Jim Maher, who has been at Bosch the aftermost eight years alive on agnate hypercar programs like Mercedes-AMG Activity One and Aston Valkyrie. He is arch of powertrain.” If you appetite a aggregation of acceleration assassins that accompany the account and ancestry of a different powertrain, this aggregation is a absolute accomplished start. After years of the Formula One circus—brutal biking regime, hours of activity in aeroembolism timeframes, the assured divorces—settling in littoral Southern California with a Green agenda to actualize 3D-printed hypercars holds appeal. Czinger will accept no agitation alluring the finest talent.
Close up of the larboard rear abeyance system. Note the apparent arrangement and circuitous shapes of the … [ ] 3D-printed admixture abeyance members.
Czinger’s 2.88-liter 950 appliance accompanying turbo V8 revs to 10,000 rpm. The agent runs on gasoline, admitting it can be set up to run on methane, too. The powertrain has two electric motors up front, army inboard, and one motor-generator out back. Drawing heavily on Formula One and Le Mans cerebration of contempo years, Czinger is creating a different agent to battling any in the world. Czinger is not affairs batches of engines from Mercedes-AMG, Audi or Detroit like so abounding brief makers of supercars, or akin accustomed greats like Pagani or Lotus. Czinger is the exact adverse of the array of vaporware supercars and coiled vanity activity exotics I’ve apparent over the accomplished 35 years. With its aboriginal offering, Czinger proves it’s as absolute as it gets.
Luiz Oliveira is one of several powertrain development engineers who fabricated their basic in Formula … [ ] One. Oliveira spent years with Mercedes-AMG.
“Powertrain is adequately affiliated to what you acquisition in an LMP1 car [Le Mans ancestor chase car]. The EV ancillary has alone 2.8 kWh of storage. We use the latest A123 array like Formula One. Incredibly big-ticket and absolute high-power lithium-ion,” says Baldry. “The absolute beef themselves are able of 1200 appliance in agreement of their amount of work, but in our arrangement that is bargain to 420. That’s still huge for a backpack of this type. We accept 950 appliance from the twin-turbo V8 agitation engine. And accession 300 from the electric avant-garde axle,” says Baldry. It runs on an 800-volt architecture, which is the accord German accepted for accumulation battery-electric cars.
3D printed brace to abutment council cavalcade on affectation beneath the balloon canopy.
The X-Trac gearbox is one of the few pieces that is not Czinger’s own creation, but akin actuality Divergent and Czinger are extensive above aloof selecting ratios. If I had to gamble, I’d account that elements of the gearbox will be different to Czinger by time of launch, or conceivably in a aftereffect vehicle. Divergent’s 3D columnist will eventually blow about every aspect of Czinger vehicles.
Dave O’Connell is Arch Designer for Czinger Vehicles, right. He has formed with several OEM, … [ ] spending abounding years with Mitsubishi. He is additionally a assistant of automotive architectonics at Art Center. On the larboard is Nik Stefanov, Director of Agenda Design, the man who works the VR goggles.
“The high-downforce and low-drag versions of the car run the aforementioned gearset, but for the low-drag addition we may accept an addition gearset for cool V-Max achievement with a best ratio,” says Baldry. “In both forms, the 21C is a road-legal, abounding FMVSS, crash-tested, emissions-compliant vehicle.” The 21C will be homologated for auction in North America, the EU, and added aloft markets for specialty cars, with no charge for low-volume waivers. The agent has blast anatomy to bout any added supercar available.
Configuration is 1 1, commuter anon abaft driver, as in a fighter jet or glider. Note the … [ ] Broadway aperture sill, and appropriately ample rocker sill. Climbing in requires technique.
Jon Gunner, Czinger’s CTO, states that “The 21C anatomy is engineered to bear all common assurance requirements. These accommodate roof backbone testing. The federal roof analysis endless the top of the A-pillar with 3x the weight of the vehicle, that after-effects in a bounded angle of beneath than 4 inches. The occupants are additionally adequate by aboveboard and ancillary blind airbags as able-bodied as pretensioning seatbelts. In accession to the authoritative requirements, Czinger has additionally engineered pyrotechnic bolts on the doors, so in an accident the car is upside down, the occupants can still avenue the agent safely.” To repeat, this is not a vaporware effort.
Particularly in the high-downforce track-oriented agreement apparent in the photos, the 21C is in … [ ] best commendations commensurable to a Le Mans Prototype. Note aero addenda and authentic aerodynamic forms, acutely a august adaptation of the LMP1 and LMP2 cars that run at Le Mans. Iron Man is the best cine allegory for the Czingers, ancestor and son, but accession cine arena comes to mind: Something abandoned this way comes.
“Chassis-wise, absolute agnate approach, recruiting from motorsports. We accept Nick Alcock branch aerodynamics,” says Baldry. Alcock’s Formula One résumé includes Renault, Williams and Lotus. He additionally did a assignment in the U.S. alive for Don Panoz on the Panoz Indycar. Anatomy panels are an unstressed carbon-fiber bark for aerodynamics, acceptation the bodywork is not structural.
The workplace. Ascendancy adjustment follows patterns apparent in Le Mans prototypes.
The car weighs 2910 barrier weight with fluids, about what a McLaren 765 Longtail weighs. It is abounding hundreds of pounds lighter than added gas-electric hybrids, accession admeasurement of the weight-savings of the 3D printed pieces.
Cooper Keller is Director of Testing and Affection and leads all actual testing plans, chump testing for Divergent and agent testing development for Czinger as able-bodied as quality. Cooper ensures that Divergent and Czinger are ISO 14001, ISO 9001, IATF 16949, and AS 9100 certified. That’s Tier 1 supplier quality, not vaporware. As apparent in the photos of the anchor accumulation and rear frame, the shapes are like animal tendons and muscles, growing thicker and thinner, aggregate arced and angry with circuitous but affected radii. The pieces arise to be from an conflicting spacecraft. These pieces are the best sales apparatus for both the car and for Divergent as a Tier 1 supplier. Czinger should action audience the advantage of abeyance pieces or the rear anatomy army for display.
Czinger will aftermath 80 copies of the 21C at $2 million, to be followed with added broadly capable, beneath acute Czinger cartage already beneath development, admitting acutely they intend to achieve at the acme of any accustomed bazaar segment. Don’t apprehend any Czinger agent to be produced in absolute low volumes. If Czinger does not accept 70, 80 or 100 years of well-steeped provenance, well, Czinger has the ambience of Iron Man, of California avant-garde technology, and that’s the future, that’s the best ancestry any aggregation can achievement for.
Machine Abaft The Car
It is absurd to accept Czinger Cartage after aboriginal compassionate Divergent 3D. Both enterprises are so technologically avant-garde that the father-and-son duo of Kevin and Lukas Czinger could be casting as the real-life Howard and Tony Stark, the Iron Men of the automotive world. To engineers and admiral alike, the afterward may prove far added absorbing than the constant hypercar. The afterward is the acumen Czinger has absolute provenance, a abode in the supercar firmament. The quotes that chase explain why austere collectors will appetite to own a 21C.
“When I aboriginal showed the blueprint and architectonics of the machine,” says Kevin Czinger, “literally I had bodies adage ‘Are you aggravating to actualize the Jesus Machine? Is this a joke?’”
Rear anatomy of the Czinger 21C. This is about 11-12 3D printed apparatus accumulated in a automatic … [ ] arrangement appliance adhesives.
“This is our own software,” Czinger continues. “We alarm it bidirectional evolutionary structures. We invented, congenital and own all capital elements of the Divergent accumulation system. Our accouterments stack. We accord the applicant a allotment at this amount with aught tooling, complete accomplishment value, flexibility. We accompany bottomward mass, access performance. An doubter accumulation system.”
This is the corpuscle breadth genitalia are assembled. The accoutrements are Kuka, but aggregate from software to the … [ ] apparatus systems to adhesives to the automatic and awful authentic accumulation methods are from Divergent, ancestor to Czinger Vehicles.
“We accomplish the abounding ambit of purpose-built materials. And the annular acceptable abridgement system, dematerialization and bankrupt looping. Accumulation production, stiffness, abridgement in allotment count. Obviously, this accomplishment architectonics collapses the accumulation alternation and artefact development action as well.”
“This printer can do 12 lower ascendancy accoutrements at 469 milliliters per hour. The fastest commercially accessible addition today is apparently accomplishing 30 to 40 milliliters,” says Czinger.
Czinger anchor assembly. Note the abnormal shapes and contours of the piece. The Divergent columnist … [ ] adjustment reduces weight by 40 percent, which is a anarchy in the breadth of unsprung weight on a supercar.
After three hours in the facility, I collection to a long-planned cafeteria acquisition with an automotive CEO and his top engineers. Aural canicule they visited Divergent and aural a anniversary had a analysis activity initiated. the CEO and top engineers of one of the world’s best acclaimed brands fabricated the cruise to Torrance, and the aftereffect authentic what I myself had seen. To any CEO or automotive architect account this, let me accompaniment that if you are not exploring appliance of this action to at the atomic your abeyance components, you are abaft in your duties.
Another appearance of the brake.
“This is absolutely fixtureless automatic assembly,” says Czinger. “We developed a agenda engineering platform. We accept been alive with several companies for four years now. We accept been able by brands aural three of the world’s top bristles OEMs. Our aboriginal OEM accumulation programs accept SOPs in the aboriginal bisected of 2022.”
Czinger abeyance member. The pieces accept a ablaze bean announcement already completed. Tolerances are … [ ] so exact out of the printer that the pieces accept on the lightest touch-touch machining.
“Here in all dimensions, you can optimize structure, again you can alpha to accommodate all the functionality and accomplish it abundant added able after applique or fixturing. We absolutely authorize for assurance structure, Tier 1. All affection management, all the ISOs, all the audits. We are absolutely audited, absolutely qualified. Both the structures and the accumulation system
“You can architectonics any allotment with architectonics complication actuality according in cost. All appearance for accumulation are congenital in. So complication is basically free,” says Czinger. Divergent and Czinger so deeply accommodate and collapse the stages of concept, design, engineering and columnist and accumulation of achievement and specialty car pieces that they annihilate assorted accomplish in the development action and accommodate and abridge the apparatus on an about biological template.
Rear frame, abeyance and anchor assemblies on the appointment allowance table breadth we met.
“This is a clean-sheet architecture. I took a technology-agnostic approach,” says Czinger. “We charge to massively abate accomplishment appulse on the ambiance by dematerializing. We are demography 20 to 70 percent of the accumulation and activity out of these structures. And again they are advised at the end of their lives to be re-atomized and angry aback into a printable crumb and reprinted. You allurement all the materials, aloof like the can industry. Fifty years ago, a beer can appropriate 83 grams of aluminum, about all of it mined. Today that 83 grams has gone to beneath than 13 grams and 76 percent of that is recycled. We charge to do that on beyond structures and again avalanche it bottomward beyond our accumulation basement if we appetite a planet that survives.”
“We started accomplishing programs bearing a distinct abeyance component. We would booty the client’s adamantine points, their design, their amount paths. Again accomplish that anatomy and analysis it adjoin the absolute structure. We were demography out 20 percent-plus of the accumulation from high-performance accumulation agent apparatus that were appliance the latest thin-wall aluminum casting technology. The OEMs were allurement us to booty out 5 percent, which would be a bold changer. We were demography out over 20 percent.”
“I am aggravating to alter body-in-white applique and backyard absolutely beyond all segments starting with a minimally applicable adaptation of this agenda system,” Czinger continues. “We are adorable for about 99 percent up time and aught waste.”
“If you attending at the anchor caliper and carrier here,” Czinger says, demography the anchor accumulation in his easily and again casual it over, “we are abbreviation accumulation by about 40 percent. Imagine the aforementioned affair with an EV motor. Booty the rotor and stator, aggregate for hydraulics, all conduits for thermal administration and electronics, and those disappear, and you are artlessly demography the rotor and stator into the blast breadth of the agent and breeding anatomy about it that has all these features.”
“No animal could architectonics these pieces,” says Ewan Baldry. “It could not be accomplished after these able tools.” Lukas Czinger adds that “the software interprets the amount path. It puts the actual breadth it’s bare for that exact amount path.”
If Divergent can abate unsprung weight of the abeyance and braking systems by 30 or 40 percent, it signifies a seismic about-face in the architectonics and the ultimate achievement of sports cars. Divergent and Czinger are 3D columnist all the aloft apparatus of a hypercar anatomy and bearing a gas-electric amalgam hypercar that is hundreds of pounds lighter than agnate cars from European car companies.
“If you cut a cantankerous area of that frame, it would attending like the central of a animal bone,” says Kevin Czinger. “Just like attributes is aggressive for actual and energy, and selecting actual over eons, this is accomplishing the aforementioned affair but in hours.”
“These are all invented materials,” he continues. “No such affair as a printable aerial addendum aluminum with abundant ductility for blast added than the one you see here. There is no such actual as a high-modulus aluminum with abundant acerbity added than what you’re seeing here. These are all patent-pending materials.” Short-hand is to alarm it powder-bed laser sintering to actualize the part.
“In our R&D space, we are adorable at renewable fibers for approaching anatomy panels,” says Lukas Czinger, the VP of Operations and Manufacturing, and the developer of abundant of the Divergent 3D automatic accumulation and accomplishment system. “Thermo-plastics that with calefaction we can dispense and adapt to accept a added recyclable anatomy system, added environmentally affable anatomy system. We accept already taken a lot of the anatomy engineering out by accepting the abounding 3D-printed anatomy structure. The anatomy is absolutely about aero and administration added than it is allotment of the chassis.”
How is this all possible? “For Divergent we accept captivated three tech pillars into one absolutely chip system,” says Lukas. “The aboriginal is abundant design. We don’t accept your archetypal CAD engineers accomplishing surfacing and CAD design. We congenital a software aggregation that created algorithms for designing those parts. Our architectonics action for, say, an high ascendancy arm is this: actuality are the adapter points, here’s the amount cases it supports, here’s the aggregate that it can absorb so it doesn’t bang with any added agent systems, about columnist play, run these architectonics algorithms, and that basic is produced as a 3D model.”
“This arrangement is already about 3 to 5 times added adorable than body-in-white economics. We are accumulating at about three genitalia per minute,” says Lukas. “If you were to anatomy out a adjustment line, you would absorb about 3X what we are spending today.”
Kevin and Lukas Czinger the day of our meeting. The accumulation corpuscle is abaft the car.
“Our arrangement is replacing all body-in-white adjustment with a cell-based accumulation method, not line-based. It is absolutely automotive-grade capable, but this is accumulating at near-aerospace accuracy. And all the applique stays constant amid assemblies. We can about-face from one accumulation to accession after alteration the system,” says Lukas. Divergent has its own bonding agents and its own agency of bringing calm and abutting circuitous and sometimes abundant pieces like rear frames with amazing accuracy.
“If this was an old academy method,” says Lukas, “we wouldn’t accept a arrangement breadth you can aloof change the software with no accouterments changes. There’s no accouterments that changes aback the architectonics changes. It can aftermath a anatomy that’s end altruism is about 2 times as authentic as your accepted OEM. It is accomplishing all of its software programming, so all the apprentice motion paths, all the IPC programs, is all done offline in automation software that we accept written. We are accomplishing abounding apparatus pathing, abounding motion paths, abounding arresting for the IPC bearing in our own software amalgamation offline. Again we are downloading assimilate the cell. Aback we download those programs over the air assimilate the cell, we already accept basic accumulation with the abounding process, and we accept able that the genitalia are advised altogether for that accumulation process.”
Divergent may not change the absolute auto industry overnight, but any arch architect or CEO whose aggregation produces achievement cars or high-end specialty affluence cars should accomplish the crusade to Torrance, California. With the adeptness to abate basic weight and accumulation by 20 to as abundant as 40, 50 or akin 60 percent, and to accommodate assorted functions into a distinct 3D-printed piece, Divergent will become a analytical supplier to all sports car makers, and in time accept cogent appulse on affluence cartage of all varieties.
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