New McLaren W1 features 3D printed suspension components | VoxelMatters - The heart of additive manufacturing

Oct 31, 2024

The new McLaren W1, the successor to the iconic McLaren F1 and P1, features groundbreaking innovation in both engineering and design. At the heart of this supercar lies the all-new MHP-8 4.0-litre twin-turbo V8 engine, part of a High-Performance Hybrid powertrain that produces an astonishing 1275PS. The W1 combines this immense power with McLaren’s signature lightweight design and cutting-edge aerodynamics, creating a road-legal supercar capable of delivering track-level performance. The key to this achievement is the McLaren Race Active Chassis Control III system, which features an active inboard heave suspension, 3D printed titanium components, rear active drop links, and adaptive damping. This advanced suspension setup allows the W1 to maintain remarkable stability and cornering prowess, whether on the road or the track. The car’s front and rear double wishbone suspension design further enhances the dynamic driving experience, providing an ideal balance of precision and comfort.

The McLaren W1 not only pushes the boundaries of supercar performance but also represents the future of automotive engineering through its adoption of cutting-edge technologies. Following in the footsteps of Bugatti Rimac and Divergent’s own car brand Czinger, McLaren Automotive recently became the latest hypercar manufacturer to embrace Divergent Adaptive Production System (DAPS) technology and additively manufactured parts. The UK automaker has entered into a multi-year collaboration with Divergent Technologies, Inc., a California-based industrial digital manufacturing company, further to develop the use of additive manufacturing in vehicle production. This collaboration aims to enhance McLaren’s vehicle performance, sustainability, and production efficiency.

Divergent’s revolutionary DAPS technology can enable McLaren to integrate more complex and innovative designs into its vehicle architecture, particularly in its 3D printed suspension components. This system enables McLaren to significantly reduce the weight of critical structures while achieving better manufacturing efficiencies and supporting a more sustainable supply chain. The 3D printed titanium components used in the W1’s suspension system—such as the front uprights and wishbones—further highlight McLaren’s commitment to leveraging cutting-edge technology to improve performance and reduce weight. These parts, designed and produced through additive manufacturing, are key contributors to the W1’s exceptional handling and dynamic capability.

The W1’s duality of character—being equally thrilling on the road and the track—is accentuated by its active aerodynamics. The active front and rear wings, along with the McLaren Active Long Tail, dynamically adjust based on driving conditions, helping the car generate up to 1,000kg of downforce in Race mode. These aerodynamic features, honed through over 350 hours of wind tunnel testing and 5,000 points of data, contribute to W1’s unprecedented performance capabilities. In Race mode, the car’s ride height lowers by 37mm at the front and 17mm at the rear, maximizing ground effect and creating unparalleled grip and stability.

The all-new MHP-8 V8 engine is coupled with a powerful E-module, which delivers instant throttle response and contributes 347PS to the car’s total output. The combination of the V8 and E-module allows the W1 to achieve mind-blowing acceleration, reaching 0-100km/h in just 2.7 seconds and 0-300km/h in under 12.7 seconds. Despite this power, the W1 remains a rear-wheel-drive supercar, a testament to McLaren’s Formula 1 heritage and engineering prowess, providing pure driving engagement with unmatched precision.

The W1’s design is as functional as it is striking, with its body sculpted to optimize airflow for both cooling and downforce. The new McLaren Anhedral doors, a first for the brand, are not only visually distinctive but also serve to enhance aerodynamic efficiency, helping to channel air from the front wheel arches to the high-temperature radiators. The car’s rear features a prominent multi-fenced diffuser and twin-center exit exhaust, further reinforcing its track-focused design ethos.

Inside the cabin, McLaren’s philosophy of driver-focused minimalism is evident. The driver and passenger seats are integrated directly into the carbon-fiber monocoque, providing an unmatched connection between the occupants and the car. The W1 features McLaren’s smallest and flattest steering wheel yet, with integral shift lights and ergonomically placed controls for Boost and Aero functions, inspired by Formula 1 technology. The cockpit is designed to offer the perfect driving position, with adjustable pedals and steering to ensure optimal ergonomics.

In addition to its performance, the McLaren W1 offers a range of customization options through McLaren Special Operations (MSO). Virtually every aspect of the car can be tailored to the owner’s preferences, from exterior finishes to the innovative use of materials like McLaren InnoKnit, a flexible and lightweight fabric that integrates seamlessly into the interior.

The W1 is not just McLaren’s fastest road-legal car; it represents the culmination of decades of racing innovation, blending Formula 1 technology with cutting-edge road car engineering. It is the ultimate expression of McLaren’s commitment to pushing the boundaries of what a supercar can be, delivering a driving experience that is both exhilarating on the track and unmatched on the road. As the fastest-lapping and fastest-accelerating McLaren ever, the W1 is set to establish a new standard in the world of hypercars.

With only 399 examples set to be produced, the McLaren W1 offers exclusivity, performance, and engineering excellence that few other supercars can match. Its blend of advanced aerodynamics, lightweight materials, and hybrid powertrain technology ensures that the W1 will go down in history as one of the most innovative and thrilling supercars ever created.