3D-Printed Vintage 1965 Sports Car

An Oak Ridge National Laboratory (ORNL) team 3D-printed a replica of a vintage 1965 Shelby Cobra sports car for the 2015 North American International Auto Show (NAIAS) in Detroit. The project took six weeks from conception to finished product, and along with celebrating the Shelby Cobra's 50th anniversary, it acts as a demonstration of modern additive manufacturing and rapid prototyping technology. The 1,400-lb ORNL Cobra looks like a well-made Shelby replica with an updated digital display, but it hides 500 lb of 3D-printed parts made of 20 percent carbon fiber. These make up the shell, support frame, passenger monocoque, grille, and headrest brackets. The car was built at the US Department of Energy's Manufacturing Demonstration Facility at ORNL using the Big Area Additive Manufacturing (BAAM) machine developed by ORNL and Cincinnati Incorporated. ORNL says that this device can print objects larger than a cubic meter in volume 500 to 1,000 times faster than current industrial additive printers.