Ford makes largest 3D printed auto part ever created

For Ken Block's Hoonitruck

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When anyone talks about Ken Block, it’s definitely next level adrenaline inducing things. He is privy to some pretty cool opportunities, vehicles and locations. For Gymkhana 10, Block, is in a 1977 Ford F-150, powered by the GT engine, tuned-up twin-turbo EcoBoost V6. It’s a modified GT engine, going from the standard 647 horsepower to a monstrous 900 horsepower. The Hoonitruck has a special intake manifold, its personal trophy, and claim to fame. Ford says this intake manifold is the biggest metal 3D-printed auto part ever created for a running car. 

Ford and RWTH Aachen’s Digital Additive Production Institute in Germany, collaborated to research and analyze what shape would be best for the intake manifold. The printing is not a quick process, taking five days to complete. The 3D printing adds layer and layer of aluminum, to create the perfect product. Aluminum is a lightweight material, and necessitates intricate webbed design throughout the printing process. This design creates a strong, yet lightweight manifold, weighing in at only 13 pounds. 

Check out what Block can do behind the wheel of the 1977 Ford F-150 beast. Never a dull moment with the Hoonigan Team. It will be exciting to see what Block and Ford dream up for the next episode.

Ford Engineers Make Record-Breaking 3D Part to Help Bring Ken BlFord Engineers Make Record-Breaking 3D Part to Help Bring Ken Bl

Image Credit: Ford

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