Ceramic piston and rod additively manufactured for Chaos ultracar

May 6, 2022

The Chaos ceramic piston and rod, additively manufactured using XJet’s Nanojetting technology (Courtesy Spyros Panopoulos Automotive )
The Chaos ceramic piston and rod, additively manufactured using XJet’s Nanojetting technology (Courtesy Spyros Panopoulos Automotive )

Spyros Panopoulos Automotive (SPA), Acharnes, Greece, has developed what is reported to be the first additively manufactured engine piston made entirely from ceramic for its Chaos ultracar. Using technology from XJet, Rehovot, Israel, the lightweight ceramic piston and rod is said to offer extraordinary strength, hardness and resistance to thermal expansion.

The Chaos, which is currently in development, reputedly has the fastest-revving production car engine ever seen, reaching up to 12,200 RPM and 3,065 horsepower. The ultracar is expected to reach speeds of over 500 kph and acceleration from 0 to 100 kph in 1.55 seconds.

SPA founder Spyros Panopoulos explains that to make the engine a reality and support the extreme levels of performance required, the ‘anadiaplasi’ piston was designed. Anadiaplasi is Panopoulos’ proprietary method of Design for Additive Manufacturing (DfAM) in which a component takes its shape based on the forces acting on it. Material is minimised where it doesn’t support performance and added where reinforcement is needed, optimising weight while maintaining the strength and temperature resistance of the part – essential for any piston, but particularly testing in such a high-performing engine. The result is an organic complex shape that is both light and strong.

On concluding the design, Panopolous realised that to produce such complex geometry – along with the high accuracy and excellent surface finish required – the only relevant manufacturing technology was Additive Manufacturing. The company then selected XJet’s Nanoparticle Jetting technology and, in collaboration with XJet’s Greek business partner Lino 3D, selected XJet alumina material for the Chaos piston.

The Chaos reputedly has the fastest-revving production car engine ever seen, reaching up to 12,200 RPM and 3,065 horsepower (Courtesy Spyros Panopoulos Automotive)
The Chaos reputedly has the fastest-revving production car engine ever seen, reaching up to 12,200 RPM and 3,065 horsepower (Courtesy Spyros Panopoulos Automotive)

“Ceramic offers many advantages compared to other materials,” stated Panopolous. “Harder and stiffer than steel, more resistant to heat and corrosion than metals or polymers and weighing significantly less than most metals and alloys. XJet’s alumina parts will withstand the high temperatures expected to develop within the combustion chamber as well as on the fast-moving parts.”

“XJet systems are uniquely capable of producing this part in ceramic, and there’s absolutely no room for error in this project,” he added.

An advocate of Additive Manufacturing, Panopolous is putting it to use throughout the Chaos Ultracar with a reported 78% of the body being additively manufactured, as well as other crucial elements such as the engine block, camshaft and intake valves.

“We are proud to be using such progressive technology in our Ultracar,” Panopolous added. “Our projects push performance to the extreme and so we are extremely selective about the materials and technologies we use. I believe this is the first-time ceramic AM is being used in motorsport and I feel privileged to take that pioneering step.”

Haim Levi, XJet VP Strategic Marketing, concluded, “SPA is taking ceramic Additive Manufacturing and Design for AM – DfAM – to the edge and beyond with their work on the Chaos Ultracar. We’re extremely proud to be part of such a trailblasing project by offering the top-level capabilities of our technology and system. Designers and engineers from a wide range of industries and applications are exposed to new options now opened for them. We expect the Chaos project ceramic piston to ignite their creativity and imaginations and push the limits in the automotive industry and beyond.”

www.xjet3d.com

www.spyrospanopoulos.com

The Chaos ceramic piston and rod, additively manufactured using XJet’s Nanojetting technology (Courtesy Spyros Panopoulos Automotive )

In the latest issue of PIM International…

Download PDF

Extensive MIM, CIM industry and sinter-based AM industry news, plus the following exclusive deep-dive articles and reports:

  • Calling all product designers: Discover what Metal Injection Moulding could do for you through these award-winning parts
  • Binder Jetting of a dual-phase steel: Process insight and optimisation using the Master Sintering Curve
  • The rise of filament-based metal AM: New materials and machines present opportunities for MIM producers
  • Sinter-based Additive Manufacturing at the 20th Plansee Seminar on Refractory Metals and Hard Materials
  • Ceramitec 2022: Opportunities abound for producers of technical ceramics by CIM and AM

The latest news from the MIM, CIM and sinter-based AM industries

Don't miss any new issue of PIM International, and stay up to date with the latest industry news. Sign up to our fortnightly newsletter.

Sign up

News from the industry…

    Discover our magazine archive…

    The free-to-access PIM International magazine archive offers unparalleled insight into the world of MIM, CIM and sinter-based AM from a commercial and technological perspective through:

    • Reports on visits to leading part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news

    All past issues are available to download as free PDFs or view in your browser.

     

    Browse the archive

     

    Looking for suppliers of materials, production equipment and finished MIM, CIM or sinter-based AM parts?

    Discover suppliers of these and more in our advertisers’ index and buyer’s guide, available in the back of PIM International.

    • Metal powders
    • MIM, CIM & AM parts producers
    • Binders & feedstocks
    • Feedstock mixers
    • Furnaces & furnace supplies
    • Atmospheres & gas generation
    • HIP systems & services
    • Injection moulding machines
    • AM technology
    • Debinding systems
    Download PDF
    Share via
    Copy link
    Powered by Social Snap