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No expense spared: Bugatti explains how it 3D-prints exotic metal parts

Bugatti deputy design director Frank Heyl told Autoblog his team doesn't balk at using the most expensive materials available, and he meant it. The company described how it 3D-prints titanium and alloy parts to save weight. Look closely at the back end of the 304-mph Chiron Super Sport 300+ or the agile Chiron Pur Sport and you'll spot 3D-printed titanium components. They're the intricately-designed covers installed over the exhaust pipes; they stick out from the carbon fiber diffuser. Each part weighs four pounds, which makes it 2.6 pounds lighter than the one fitted to the standard Chiron. It's one of the weight-saving measures Bugatti took to create both cars. Manufacturing the part requires firing up four 400-watt lasers that stack 4,200 individual layers of metal powder on top of each other while fusing them. The part is extremely thin in places but remarkably solid thanks to what Bugatti refers to as a "bionic honeycomb" structure, and it's capable of withstanding temperatures of up to 1,200 degrees Fahrenheit. That might sound like overkill, but keep in mind the cover is on the receiving end of a 1,500-horsepower, 16-cylinder engine. The exhaust system gets really hot, really quickly under heavy acceleration. Bugatti began using 3D printing in 2018, and now the Chiron Sport, the Divo, the one-off La Voiture Noire, and the Centodieci all use components made with 3D-printed metals. The part that covers the Sport's four visible exhaust tips (there are six in total) is notably manufactured using Inconel 718, a nickel-chrome alloy whose audial resemblance to a mid-engined model is purely coincidental; it's not a blend of molten Porsches. It's a material normally used in gas turbines, the blades attached to airplane engines, space ships, and even rocket engines. Making the cover takes several days. Engineers scan every part they produce with a computer tomograph to detect air bubbles that can get trapped between the layers during the printing process. If there are none, the part is blasted with a material named corundum, painted, and sent to the Bugatti Atelier in Molsheim, France, where it's checked yet again before it's installed on the car. Few exhaust tips have such a fascinating story to tell. "The advantage of the 3D printing process lies in the geometric shapes that are possible," said Nils Weimann, Bugatti's head of body development.

Vile Gossip: Ladies who launch

Jean Jennings has been writing about cars for more than 30 years, after stints as a taxicab driver and as a mechanic in the Chrysler Proving Grounds Impact Lab. She was a staff writer at Car and Driver magazine, the first executive editor and former president and editor-in-chief of Automobile Magazine, the founder of the blog Jean Knows Cars and former automotive correspondent for Good Morning America. She has lifetime awards from both the Motor Press Guild and the New England Motor Press Association. Look for more Vile Gossip columns in the future. The year was 2006. We were driving a Bugatti Veyron 16.4 across the Florida Panhandle from Jacksonville to Panama City, only because I couldn't convince Bugatti to let me be the first to drive its exotic powerhouse, the world's fastest car at that time, all the way across America. One gleaming example had arrived in time for the Amelia Island Concours d'Elegance, where the journos massed for their quick test drives out the front drive of the Ritz Carlton, down a short stretch of the A1A, and back to the Ritz. Not far enough for me. I wanted to take the Veyron in all of its 16-cylinder, 1,001-horsepower, $1.3-million-dollar glory on a coast-to-coast extravaganza of a road trip. Never hurts to ask. I asked. Once the Bugatti guys stopped hyperventilating, I explained that the coastal adventure would be contained wholly within the state of Florida, from the Atlantic coast to the Gulf of Mexico. My secret destination, however, was to be Vernon, Florida, home of the great Errol Morris' classic documentary about a town in the Panhandle with the highest per-capita population of citizens who'd blown off or whacked off a limb for insurance money. (Google "Nub City.") The Swiss head of Bugatti public relations thought it hilarious. He showed up in a van with a couple of German mechanics to follow us and a failed French Formula 1 driver to serve as my chaperone. I came with a photographer from Germany and one of the most infamous of bad-boy auto magazine tech editors, the irrepressible Don Sherman. Sherman had his own reason for going, and it had nothing to do with a Veyron to Vernon. Once we gave up looking for nubbies, he ordered me to veer south to the handgrip of the Panhandle, familiarly known as the Redneck Riviera. The Don was aiming to secretly execute the Veyron's first Launch Control blastoff in captivity.

Bugatti Centodieci prototype caught running the 'Ring in new spy photos

Bugatti's Centodieci prototype is evidently ready for the Nurburgring. Spies caught the development vehicle for the upcoming EB110 tribute being put through its paces on the Nordschleife and surrounding public roads. The 1,600-horsepower Centodieci supercar has been in development for a couple of years. It was originally announced at Pebble Beach in 2019, and Bugatti announced earlier this year that it had completed work on the first full-body prototype. Here it is. Bugatti hasn't bothered to disguise the Centodieci, so we can plainly see how faithful it is to the concept.  That said, there are signs that this prototype is still a long way from being showroom-ready. The body may be complete, but up close, it's a bit rough around the edges. The side blade inserts lack the more dramatic depth of the parts that were fitted to the concept, and may well be placeholders for testing purposes. Tape and wire is visible on elements of the front and rear bumpers and exhaust finishers, suggesting the presence of sensors sending telemetry to the prototype's data recorder.  The Centodieci's 16-cylinder sends its power to all four wheels through a seven-speed DCT. The EB110 it honors made do with a quad-turbo, 3.5-liter V12 making "just" 560 horsepower and putting that to the ground with a simple six-speed manual and permanent all-wheel drive. Bugatti claims a 0-60 time of approximately 2.4 seconds and an electronically limited top speed of 236 mph. That may seem low, especially since this is ostensibly a Chiron successor, but Bugatti is no longer in the top-speed-record game. All 10 examples of Bugatti's new Chiron-topping exotic are reportedly spoken for.