Rodin Manufactures a 3D-printed Gearbox for Bespoke Supercar with Metal Additive Manufacturing Solution

3D Systems AIG has successfully transferred technology to Rodin Cars for commercialization.

FREMONT, CA: 3D Systems announces that Rodin Cars, a New Zealand-based manufacturer of the ultimate track car, has selected 3D Systems metal additive manufacturing solutions to produce components for the Rodin FZero hyper car, which will be released later this year. Rodin Cars design and build entirely custom single-seat, open-wheel high-performance vehicles faster than current Formula 1 car. Rodin Cars is additively manufacturing hundreds of metal components for the Rodin F-Zero, including a first-of-its-kind 8-speed sequential gearbox with a hydraulically controlled differential. This custom component is only possible through additive manufacturing and was made possible through a collaboration between Rodin Cars' design prowess and 3D Systems' deep application expertise and additive manufacturing leadership.

A gearbox manufactured conventionally will be cast in Magnesium or machined from billet material. Not only would the resulting component be slower to manufacture, but it would also be heavier and incapable of withstanding the track's rigors. Rodin Cars wanted to transform this design into a true innovation by creating the ultimate component made entirely of 3D printed Titanium that was compact, light, strong, and durable.

Rodin Cars introduced their first high-performance track car, the Rodin FZed, in 2019, featuring a gearbox designed by Ricardo, a UK-based engineering firm. Rodin Cars envisions a brand-new gearbox with specific gear ratios and a titanium differential for the new Rodin F-Zero to enhance the exotic reputation of this new high-performance vehicle. Rodin Cars collaborate with 3D Systems Application Innovation Group (AIG) members in Littleton, Colorado, and Leuven, Belgium, to bring this one-of-a-kind design to life.

3D Systems AIG's application engineers are experts in additive manufacturing and high-value applications across various industries, including motorsports.

“3D printing allows us to design and create components otherwise unachievable using traditional methods of manufacturing,” says David Dicker, founder, Rodin Cars. “With the Rodin FZERO gearbox, we had specific criteria we wanted to meet in terms of weight and durability. Because of the size and quality required for such a large component, it was only possible to print it on 3D Systems DMP Factory 500 machine. We couldn’t source another AM supplier who was able to offer a similar solution for our needs - the print quality, volume capacity, testing facilities in Leuven, and continued technological support.”

Additionally, with 3D Systems DMP technology, Rodin Cars uses selective laser sintering (SLS) for production parts and stereolithography (SLA) to produce tooling for carbon fiber forms.

“Additive manufacturing is enabling industry leaders to defy limitations and stand apart,” says Kevin Baughey, segment leader, transportation and motorsports, 3D Systems. “As a high technology, high-performance car constructor, Rodin Cars delivers unparalleled vehicles to their customers. This is a shining example of how additive manufacturing not only enables parts to be produced that couldn’t be created through conventional methods, it is also delivering a lighter, more durable, beautiful vehicle. It’s the blending of the art of design with the science of hyper-performance cars and motorsports.”