Advanced Manufacturing Solutions for High-Performance Automotive Applications
One Team, One Workflow, from Functional Prototype to Certified Part
Five decades of motorsport and hypercar development have forged CRP Group’s distinctive capability: designing and manufacturing reliable components for severely constrained operating conditions – extreme thermal gradients, continuous vibration, chemically aggressive environments, and tight packaging.
Through a vertically integrated workflow combining Windform® SLS composites, DMLS metal alloys, ultra-precision CNC machining, and rapid sand casting, we take components from functional prototype to Low-Rate Initial Production (LRIP) – without supplier changes or material requalification.
Key capabilities
From Complexity to Monolithic Integrity
Brackets, ducts, and sealing interfaces consolidated into single monolithic components: up to 40% fewer joining points and up to 30% weight reduction vs. machined-from-solid. Validated to 5 bar and -40°C to +120°C for full structural continuity
Topology-Optimized Design for Additive Manufacturing (DfAM)
A dedicated DfAM approach from the earliest project stages maximizes stiffness-to-weight ratio and eliminates non-functional mass, enabling geometries impossible with conventional methods - critical for hydrogen-specific components and aerodynamic profiles stable beyond 340 km/h
Hybrid AM
+ CNC Workflow
Additive manufacturing for complex geometries, 5-axis CNC for critical mating surfaces, vapor smoothing for internal aero profiles. Everything under one roof: no supplier handoffs, no tolerance reinterpretation, consistent tolerances from prototype to production
Prototype to LRIP Under One Roof
Same materials, process chain, and team from the first iteration through dyno validation to LRIP. Vertical integration guarantees no requalification on transfer, reducing time-to-market with motorsport-grade reliability for hypercar and EV architectures
Motorsport-Grade Reliability
Hypercar & EV Engineering
Weight & Structural Optimization
Thermal Cycling & Pressure Validation
Aerodynamic & Active Aero Systems
Design and Engineering Expertise
Validation Spotlight
From Motorsport to Next-Generation Hypercars
Alpine Racing partnered with CRP Group to overcome the limitations of traditional bonded multi-part designs in the Alpenglow Hy6 hydrogen hypercar. Our team developed a monolithic Windform® SP intake plenum, optimized for hydrogen-specific pressure requirements: a single-piece structure that eliminates leakage risks, integrates complex geometries impossible with conventional methods, and withstands the radical thermal and pressure gradients of next-generation powertrains.
Beyond internal housings, Windform® composites excel in external supercar aerodynamics – from splitters to active winglets – delivering structural stability and F1-level aerodynamic efficiency under heavy downforce.
Superior stiffness and impact absorption preserve aero-profile integrity, enabling adjustable components such as louvres and motorized winglets for drag and stability control.
Engineering Excellence: Monolithic Components for Extreme Performance
Monolithic Integrity Under Extreme Operating Stress
High-performance components – such as intake manifolds, cooling ducts, and electronic housings – require monolithic structural integrity and precise material control under extreme stress. CRP Group’s integrated process and material approach ensures high stiffness, structural continuity, and dimensional stability. This eliminates issues like differential thermal expansion, adhesive creep, and delamination, while maintaining sealing integrity from -40°C to +120°C and pressure resistance up to 5 bar.
Durability, and Aerodynamic Optimization for High-Speed Applications
Ultra-precision CNC machining on flanges and sealing faces enables direct sensor integration without secondary bonding, while Windform® composites provide inherent resistance to oil, water, and fuels – a property of the material itself, not dependent on temporary coatings. Validated in extreme environments like the 24 Hours of Le Mans at 340+ km/h, these components ensure aerodynamic stability through high stiffness and impact absorption. The seamless transition from prototype to LRIP guarantees uninterrupted development, making CRP Group’s solutions ideal for racing, endurance, and high-stress industrial applications.
Materials Expertise for Automotive
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