British automaker McLaren Automotive has recently announced a partnership with California-based manufacturing technology company Divergent Technologies to jointly develop a series of 3D-printed suspension components for its latest high-performance hybrid supercar, the McLaren W1. This collaboration utilizes additive manufacturing technology to produce structurally optimized parts—including front upper control arms, aerodynamically styled lower control arms, and front wheel knuckles—that meet stringent standards in rigidity, durability, and aerodynamic performance.
The core technology of the project is Divergent’s Adaptive Production System (DAPS), a digital manufacturing platform enabling moldless production of vehicle components. Unlike traditional manufacturing methods that require custom molds, DAPS allows direct production of parts based on digitally optimized designs, thereby accelerating iteration cycles, enhancing design flexibility, and reducing material waste.
A McLaren Automotive official statement noted: “Divergent’s innovative design and manufacturing methods have enabled our engineers to rapidly iterate on design solutions, advancing the development of breakthrough structural suspension components for this supercar. These components have made significant contributions to the W1’s exceptional vehicle performance and driving experience.”
The W1, commemorating the 50th anniversary of McLaren’s first F1 World Championship, is equipped with a 4.0-liter twin-turbocharged V8 engine and a hybrid system, delivering a combined output of 1,275 PS (1,258 horsepower) with a top speed of 350 km/h. The car has a dry weight of only 1,399 kg.
During the W1’s development, Divergent was responsible for developing a Formula 1-style front suspension system directly integrated into McLaren’s carbon fiber Aerocell monocoque chassis. These components are manufactured using laser powder bed fusion technology. While this technology is often used for prototyping, Divergent has applied it to mass production of functional structural parts by integrating generative design algorithms, artificial intelligence, and robotics.
The W1 project marks Divergent’s first integration of aerodynamic lower control arms directly into the vehicle’s structural framework. Beyond aerodynamic considerations, weight optimization was a key goal, with the design team meticulously evaluating every gram of material to achieve the perfect balance between weight reduction and performance.
“Our structural team essentially became an extension of McLaren’s suspension and chassis team. They provided design spaces, no-go zones, stiffness requirements, and load conditions, after which our algorithms generated optimal topologies,” explained Cooper Keller, Chief Project Operations Officer at Divergent. The two parties plan to expand their collaboration to the entire vehicle in the future, fully applying advanced manufacturing technologies “from bumper to bumper, corner to corner.”
In industry developments, Australian thermal management solutions company Conflux Technology announced in June a partnership with Italian supercar manufacturer Pagani to tackle thermal management challenges in the Utopia model’s transmission system. The car is equipped with a 6-liter twin-turbo V12 engine developed by Mercedes-AMG, paired with a custom Xtrac seven-speed transmission. Bentley Motors recently released the limited-edition Batur luxury grand tourer “Black Rose,” which innovatively features 18K recycled rose gold 3D-printed components, developed by the Mulliner division in collaboration with precious metal supplier Cooksongold, with a maximum precious metal usage of 210 grams per vehicle.
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