Koenigsegg 3D-Printing for Production Vehicles

Koenigsegg with Printed Parts

We’re not surprised to see a car manufacturer using 3D-printing technology, but we think this may be the first time we’ve heard of 3D-prints going into production vehicles. You’ve likely heard of Christian von Koenigsegg’s cars if you’re a fan of BBC’s Top Gear, where the hypercar screams its way into the leading lap times.

Now it seems the Swedish car manufacturer has integrated 3D printing and scanning into the design process. Christian himself explains the benefits of both for iterative design: they roughed out a chair, adjusting it as they went until it was about the right shape and was comfortable. They then used a laser scanner to bring it into a CAD file, which significantly accelerated the production process. He’s also got some examples of brake pedals printed from ABS—they normally machine them out of aluminum—to test the fits and the feeling. They make adjustments as necessary to the prints, sometimes carving them up by hand, then break out the laser scanner again to capture any modifications, bring it back to CAD, and reprint the model.

Interestingly, they’ve been printing some bits and pieces for production cars out of ABS for a few years. Considering the low volume they are working with, it makes sense. Videos and more info after the jump.

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Motobrain: A Bluetooth controlled PDU

motobrain

If you’ve ever considered modding your vehicle’s electrical system, [Josh Oster-Morris's] Motobrain PDU (power distribution unit) might make life easier by providing precision control and protection for auxiliary 12V outputs in your car, bike, boat, etc. Once the Motobrain is paired to a phone over Bluetooth, a companion app displays real-time telemetry and lets you program up to 8 output channels.

Each of these 8 outputs can be directly controlled in the app, but the real power lies in the 4 programmable inputs. Here you can tie systems together and dictate exactly how one should respond to the other, e.g. detecting high-beams and disabling the auxiliary light bar you added. There’s even a “delayed on” option. Programming also has PWM capabilities, so flipping a switch could raise the brightness of some lights over 4 levels of intensity. If those lights are LEDs, the Motobrain can also provide constant current to specification. Each circuit can supposedly handle 15A continuous current and has a programmable circuit breaker, which would make fuses optional.

You can watch an overview video after the break to get a better idea of how it all works, but stop by [Josh's] project blog to see all the features explained across multiple videos and blog posts as they are developed and tested.

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Kinetic sculpture takes a page from modern life

The blurry image above is a snap of toy cars as they zoom around a multi-lane, multi-level, maniacal-maze called Metropolis II. We originally took a look at the video after the break (do it now!) but found more information on [Chris Burden's] kenetic sculpture in this NYT article. He and eight studio artists began work on the project back in 2006. They built 1200 custom designed cars and gave them a huge city to traverse, with up to 18 lanes at times. The work is not yet done, and the video below is dated (having been filmed in 2009), but project is slated to conclude in about two months and the installation has already been snapped up by the Los Angeles County Museum of Art.

And here we thought this was the product of an out-of-work packaging system design engineer. Nope, it’s art, and it certainly eclipses other kinetic sculptures we’ve seen.

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Stop light for HotWheels

stop

[Paul] wrote in to show us this little project he did for his kids. His children love playing with their toy cars. In an effort to give them even more fun while playing, [Paul] built a stop light for them. He’s using an ATtiny13 to run them and has the source code available on his site. Not only did the kids get a new toy, he got an excuse to go build something in his workshop.

Using MatchBox cars as a switch

cars

[atduskgreg] posted this interesting setup to flickr. He’s using two toy cars as a switch. He has wired into their metal undercarriages so when they collide, the circuit closes. We’ve seen some pretty nifty home made interface items, but usually they are posted with a clear purpose or a project. This one is a little puzzling. Does he intend to keep using the cars or was he just fooling around? Is he working on a toy that does something when they crash? Was he merely bored and wanted to see what he could attach to his Arduino. We may never know.

Escape From Berkeley

Escape From Berkeley (By Any Non-Petroleum Means Necessary) is an alternative-fueled road rally that starts October 10th and ends October 13th. The rally begins in Berkeley, California, and finishes in Las Vegas, Nevada at the Sahara. Contestants are required to use any fuel other than petroleum, and using only those fuels scavenged “for free” along the way. Fuel cannot be purchased. Judges will present awards for both artistic and technical achievements. If you want to get in on the action, there are a number of ways to participate, from registering your vehicle to volunteering for the event or even sponsoring the route “by the mile” or by landmark.

[via Laughing Squid]

How to hotwire your own car

Ignition switch
Picture this scenario: it’s 2 AM, you’re stuck somewhere you’d rather not be, and you’ve lost your car keys. If you can’t call the Auto Club, what do you do? Hotwire your own car, of course. Wired.com has a wiki article detailing all the things you need to do to get that car running: how to identify which wires to connect, potential pitfalls of newer cars that require an RFID chip in the key, and so on. Of course, hotwiring a car that doesn’t belong to you is illegal, but this is one of those skills-like lockpicking-which just might come in handy in an emergency.

[Photo: D.B. Blas]

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