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Stratasys has announced that its Dimension 3D printers and its Fortus 3D printers have played a critical role in the development of the new Mini John Cooper Works World Rally Car (WRC).

The Mini Cooper WRC team used the additive manufacturing machines to create a full-scale mock-up of the vehicle directly from the computer-aided design (CAD) files and it used the technology extensively on other assemblies and components of the vehicle.

The Mini WRC team relied heavily on 3D printing throughout the car’s two-year development cycle.

To design the test car, engineers used Stratasys’s FDM 3D printing technology to create large parts of the engine bay, gearbox, steering assembly, vehicle interior and even engine components, such as intake valves.

In addition to prototyping parts for the test track, the Mini WRC team even produced some end-use parts for the finished car.

One of the most visible of these is the ergonomically styled gearshift display and control panel, mounted on the steering column.

The development of the car, which will be featured in this year’s World Rally Championship, has shown the Mini WRC team the importance of 3D printing in saving time, reducing tooling costs and enabling more design freedom of complex geometric parts.

The Mini WRC team used Dimension 1200es 3D printers and Fortus 400mc 3D printers with polycarbonate and ABS materials.


Over 25 years, Stratasys’ customers have proven the power of 3D printing to accelerate product development, elevate quality and lower costs. And today they’re shaping the world around us by reimagining what’s possible in fields like health care and aerospace.

Additive manufacturing frees you from many conventional design and manufacturing constraints, producing durable tools, patterns, moulds and production parts that may not otherwise be feasible. Achieve the strength, durability and accuracy of traditionally manufactured parts – in less time.

So, if you’re driven to create better products, better processes or even a better world, Stratasys additive manufacturing solutions empower you to work smarter, think faster and innovate more freely.

Stratasys has been at the forefront of 3D printing innovation for more than 25 years. Stratasys is shaping lives by helping researchers and health experts expand human knowledge and advance health care delivery. Stratasys is fueling the next generation of innovation through its work in aerospace, automotive and education.

Stratasys is trusted worldwide by leading manufacturers and groundbreaking designers, makers, thinkers and doers. As a proud innovation partner, Stratasys offers the best mix of technologies, deep industry expertise – and the most flexible implementation options to meet customers’ needs – whatever shape they may take.

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