BUILT TO DEFY LIMITS
From 3D Printed Pattern to Titanium Masterpiece. The Hypercar Way
When Kepler Motors set out to build the MOTION, a hypercar capable of accelerating from 0 to 60 mph in under 2.5 seconds, they knew traditional manufacturing wouldn’t be enough. For critical parts like the suspension uprights, which connect the wheels to the car’s double wishbone pushrod suspension, they demanded maximum strength and minimum weight – with no design compromises.
That’s where CRP firms came in.
THE TECHNICAL HEART OF THE PROJECT
Freedom to Redesign
Kepler’s engineering team reimagined the upright from scratch, designing it for performance first, not around manufacturing constraints. By working with CRP USA and CRP Meccanica, they gained access to a hybrid production chain: additive manufacturing, investment casting, and CNC machining.
Using Selective Laser Sintering, CRP created the complex upright geometry as a 3D printed pattern – free from the limitations of traditional mold design. This allowed for internal features, smooth load paths, and tight integration with surrounding systems.
Precision in Titanium
The printed pattern was used to cast the upright in titanium, a material chosen for its superior strength-to-weight ratio, rigidity, and heat resistance. Unlike aluminum – often used in uprights but bulky and less durable – titanium enables thinner walls and greater design flexibility without compromising mechanical integrity.
CRP Meccanica then performed high-precision CNC machining to meet the demanding tolerances required for proper alignment of bearings, linkages, and fasteners. Every face, hole, and angle had to be machined to perfection.
Structural Optimization
Multiple load cases were validated through Finite Element Analysis (FEA), ensuring the part would handle extreme braking, cornering, downforce, and acceleration – all of which act simultaneously on a hypercar upright.
The result: an elegant, lightweight structure that is functional, robust, and ready for racing-grade street performance.
Integrated Expertise
3D printed pattern
Titanium casting
CNC machining
FEA validation
Dimensional and non-destructive testing
Traceability from raw alloy to finished part
All under one coordinated process.
THE RIGHT MATERIAL, THE RIGHT TEAM
Kepler Motors selected CRP firms because of its Formula 1 DNA and ability to manage complexity. The result was a part no other supplier could have achieved:
lighter, stronger, more accurate, and delivered on time.
CRP Meccanica made design freedom real – without compromise, delay, or error.