In October, McLaren introduced the W1, the successor to its P1 hypercar. While the W1 shares a plug-in hybrid powertrain built around a twin-turbocharged V-8 engine with the P1, it diverges significantly in other aspects, particularly in its chassis architecture.
A distinctive feature of the W1 is its utilization of 3D printing to create lightweight yet robust suspension components. This includes the front upper wishbones, aerodynamically designed lower wishbones, and the front uprights.
For the development of these parts, McLaren collaborated with Divergent Technologies, a U.S.-based company renowned for its expertise in 3D printing complex components across various industries beyond automotive. Divergent’s founder, Kevin Czinger, also established the hypercar brand Czinger, which focuses on vehicles incorporating 3D-printed elements throughout their structure.
McLaren W1 suspension
The 3D printing method involves layering metal in powder form, which is then fused together with lasers. Once fashioned, the parts are placed in a heat treatment furnace to remove any residual stress. Special software designs these components using minimal material, often resulting in the somewhat organic forms they may take.
Integrated into the W1, the front suspension components—including pushrods equipped with inboard dampers, torsion bars, and heave dampers—are attached directly to the car’s central carbon-fiber tub, negating the necessity for a front subframe. This design choice contributes to additional weight savings while facilitating improved airflow beneath the vehicle.
McLaren and Czinger are not alone in the hypercar arena when it comes to integrating 3D printing for suspension components. Ferrari, too, employs 3D printing for suspension elements in its competing F80 hypercar. Bugatti has been utilizing 3D printing for years in its hypercars, including suspension parts for the latest Tourbillon model.
Deliveries of the W1 are set to begin in 2026. Priced starting at $2.1 million, all 399 units planned for production have already been accounted for, according to McLaren.
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