In a bold leap forward for both performance and production innovation, McLaren has unveiled a cutting-edge manufacturing breakthrough for its forthcoming W1 hypercar: 3D-printed front suspension components. The move marks a historic shift in the use of additive manufacturing for structural vehicle parts—not merely for prototyping but as a core element of a production-ready supercar.
At the heart of this engineering feat is a high-tech collaboration with California-based Divergent Technologies, a leader in digital industrial manufacturing. The partnership underscores how next-generation technologies are being woven into the DNA of modern hypercars, as McLaren prepares to debut the W1 at the 2025 Goodwood Festival of Speed.
A Formula 1 Spirit in a Road-Ready Hypercar
The McLaren W1—a $2.1 million marvel producing a staggering 1,257 horsepower—is not just another addition to the automaker’s elite stable. Designed to commemorate the 50th anniversary of McLaren’s first Formula 1 championship victory, the W1 blends racing DNA with road-going refinement.
Key to this transformation is its front suspension system: a Formula 1-inspired assembly directly integrated into the carbon fiber Aerocell monocoque chassis. McLaren engineers worked closely with Divergent to design components that are not only lighter and stiffer but also optimized for aerodynamic performance.
These parts include the front upper wishbone, the aerodynamic lower wishbone (or “perform”), and the front upright—all prominently visible and functionally critical. Will Tabbah, McLaren’s Principal Chassis Engineer, said the W1 is “all about aerodynamics,” a principle that guided the entire suspension design.
From Powder to Performance: The Divergent Edge
At the core of this advancement is Divergent’s proprietary Divergent Adaptive Production System (DAPS), a fully digital, design-agnostic production system that eliminates the need for traditional tooling or fixed fixturing.
Using laser powder bed fusion, the process starts with finely milled powdered metals. High-powered lasers and precision optics fuse these particles layer by layer, resulting in ultra-complex, durable structures that conventional methods cannot produce.
Cooper Keller, Divergent’s Chief Programs and Operational Officer, emphasized that this method allows McLaren to iterate designs rapidly and precisely. “Removing even a single gram could risk the entire part’s integrity,” Keller said, pointing to the delicate balance between weight and structural performance.
Divergent’s software algorithms received design inputs from McLaren—like spatial restrictions, performance targets, and load expectations—and produced optimized component geometries within hours, instead of months.
Why This Matters: A Manufacturing Paradigm Shift
Historically, 3D printing in automotive design has been confined to prototype mockups or non-load-bearing interior elements. However, McLaren and Divergent have flipped that convention. These 3D-printed suspension arms aren’t placeholders—they’re the real thing, integrated into a hypercar’s final form.
This collaboration demonstrates a major shift in how automakers could build future performance vehicles. With AI-driven design, digital simulation, and robotic production, companies can reduce time-to-market, improve testing feedback loops, and lower material waste—all while unlocking new performance thresholds.
In this case, the 3D-printed parts contribute to the W1’s F1-like handling and aerodynamic mastery, enhancing both ride dynamics and high-speed stability. The ability to fine-tune airflow over components like the wishbones—while maintaining rigidity and weight savings—creates performance benefits impossible to achieve through traditional machining.
What’s Next for McLaren and Divergent?
With all 399 W1 units already sold ahead of its public debut at Goodwood this weekend, the model has already established itself as a collector’s item and a technological benchmark.
But McLaren’s ambitions don’t stop at suspension systems. Keller expressed a desire to expand the partnership beyond individual components: “Our vision is bumper-to-bumper, corner-to-corner digital production.”
As more automakers look to embrace flexibility, speed, and precision in their manufacturing lines, McLaren and Divergent’s work on the W1 could serve as a blueprint for the future.
Final Thoughts: A New Era of Automotive Engineering
The McLaren W1 isn’t just an expression of power and prestige—it’s a statement about where automotive design and manufacturing are headed. By integrating Divergent’s AI-driven, 3D-printed parts into its core performance systems, McLaren has unlocked a level of detail, durability, and aerodynamics once thought unattainable in production vehicles.
As this technology becomes more accessible and scalable, it’s likely only a matter of time before other high-performance and even mainstream manufacturers follow suit.
In a world where every gram, angle, and iteration matters, the road to the future may very well be 3D-printed.
Highlights:
- Car: McLaren W1 ($2.1M, 1,257 hp hybrid V8, 217 mph top speed)
- Tech Partner: Divergent Technologies
- Innovation: First production use of 3D-printed suspension parts (wishbones & upright)
- Debut: Goodwood Festival of Speed 2025
- Production: Limited to 399 units – all sold
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