3D Printing

Chevrolet's IMSA, NASCAR wins today are thanks to 3D-printed parts

Chase Elliot, driver of the #9 NAPA Auto Parts Chevrolet, celebrates after winning the NASCAR Cup Series Bank of America ROVAL 400 at Charlotte Motor Speedway on October 11, 2020 in Concord, North Carolina.

Photo by Sean Gardner/Getty Images

Chase Elliot drives the No. 9 Chevrolet Camaro ZL1 1LE for Hendrick Motorsports. Antonio Garcia and Jordan Taylor drive Chevrolet Corvette C8.Rs in the IMSA WeatherTech SportsCar Championship. Their wins this weekend at Charlotte Motor Speedway were, at least in part, to the 3D printing technology that General Motors has been innovating over the last few years.

This season, the Corvette C8.R, IndyCar, NASCAR Camaro and Silverado race teams have accumulated more than 80,000 miles of competition in vehicles built with 3D-printed parts.

"Chevrolet has a long history of technology transfer between our motorsports and production teams, and this is a perfect example of our approach," said Jim Campbell, GM U.S. vice president of Performance and Motorsports. "GM's 3D-printing capability speeds up our learning cycles and, in turn, these racetrack experiences help our additive manufacturing team move one step closer to using 3D-printed parts in production vehicles."

Earlier this year, two Corvette race cars, both C8.Rs, debuted at the Rolex 24 at Daytona, each equipped with 75 3D-printed parts. Among those parts are an oil tank, tank inlet and cap, air conditioning driver cooling box and integrated hydration system, power steering pump bracket and headlight assemblies. Since then, the C8.Rs have accumulated nearly 8,000 miles of competition in seven races.

The Chevrolet IndyCar V6 exhaust system is 3D printed, which has allowed the company to eliminate failure points and increase design freedom while reducing costs. Chevrolet IndyCar engines have run over 60,000 miles since the season kicked off at Genesys 300 at Texas Motor Speedway in June.

The Silverado off-road race truck debuted at the Best in the Desert Method Race Wheels Laughlin Desert Classic in October 2019. The Silverado competes in the 1200 Stock class, which limits changes to suspension, underbody and installation of race-safety equipment. The truck's rear damper shield is made of carbon-fiber reinforced plastic protects the rear dampers. It's made in-house by General Motors. Since its debut, the Silverado race truck has accumulated 900 miles of competition in six races.

Chevrolet engineers have optimized the aerodynamic performance of their NASCAR model using full-scale wind-tunnel testing. Oover 500 3D-printed prototype parts were used in testing to develop the ZL1 1LE body, which is new for this year. The Camaro ZL1 1LE is equipped with a 3D-printed gear cooling duct, which has accumulated nearly 18,500 miles of competition in 27 races.

"By utilizing 3D-printed parts, Chevrolet Motorsports is demonstrating the many benefits of additive manufacturing, including manufacturing efficiencies, mass reduction, parts consolidation, creativity and cost savings," said Audley Brown, GM director, Materials Engineering, Additive Design and Manufacturing. "3D-printed parts can offer equal strength and durability to cast or milled components, which is critical for product development and design."

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The ZR2 is a beefy off-road pickup.

Chevrolet

Chevrolet has added a beefed-up version of its half-ton pickup to the 2022 Silverado lineup that has more capability and comfort for towing and hauling loads, traveling to hard jobs over a variety of road surfaces and a better 4WD game for backcountry travel. I recently joined the Bow-Tie brand for a 200-mile-long evaluation of the first-ever Chevy ZR2. Our day-long test drive took us from the popular desert playground of Palm Springs, located in a verdant valley surrounded by 5,000 to 10,000-foot mountains, to swaths of nearby desert. There, we traveled along a collection of dirt trails in Joshua Tree National Forest and on a 4WD mining trail to abandoned gold mines, with rugged topography that allowed us to try out the truck’s updated hardware that has been engineered to bring an ease of operation and safety for motoring over tough and technical terrain.

2022 Chevrolet Silverado ZR2The ZR2 gets several exclusive touches that set it apart from a standard Silverado.Chevrolet

Chevy has made some significant changes to the 2022 Silverado lineup from outside to in and has added Super Cruise, a hands-free drive mode that we were able to try out on local highways in the Palm Springs environs, as we also checked out different trim levels and new technologies. Updates of note are new interior styling, freshened materials and premium trims; a new dashboard and digital displays with a 12.3-inch fully digital gauge cluster and a 13.4-inch touchscreen infotainment system (with Google’s Maps, Assistant and Play Store as well as Android Auto and Apple CarPlay); and an electronic shifter mounted to the center console. However, our primary task was to focus on the all-new ZR2 that has been set up with a 420-hp 6.2-liter V-8 engine, rides on 33-inch Goodyear Wrangler Territory tires, boasts a new suspension with Multimatic spool-valve dampers, and has electronic-locking front and rear differentials. Elements of the ZR2 and this moniker have been used previously on a special edition of Chevy’s compact truck.

In addition to its functional features, the new Silverado ZR2 stands apart from its stablemates by a collection of unique design cues, including a distinctive front end with a new black hood insert; a large-sized grille with a hollowed-out ‘flow-tie’ emblem for increased air flow and integrated lighting; wheel moldings, ZR2 badges, unique 18-inch wheels and an exclusive Jet Black/Graystone leather-trimmed interior matched with an appealing dark trim. Overall, the truck looks slightly aggressive and fit. The 2022 Chevrolet Silverado ZR2 competes with other full-sized desert-running and off-road trucks from Ford and Ram. It’s only offered with a crew-cab body style and either the short- or standard-length cargo boxes with an optional Multi-Flex Tailgate. On sale now, it starts at $67,600 (plus $1,695 destination and delivery)

Chevy’s flagship off-road pickup can tow 8,900 pounds with a conventional trailer hitch and haul up to 1,440 pounds of payload, with more comfortable ride as a result of the spool-valved dampers and specially-tuned springs that bring increased wheel travel when compared to the Trail Boss trim, for instance. This also translates to improved control and greater safety on the road, which we found impressive during our highway driving. The truck has a number of new standard safety features, as well.

2022 Chevrolet Silverado ZR2The off-road can tow up to 8,900 pounds and haul up to 1,440 pounds.Chevrolet

Added to Chevy’s in-house testing of the truck in everyday driving and extremes, we learned that the new pickup has been put to the test over the past three years by Chad Hall, who is a highly-respected off-roader and noted desert racer. The production truck and Hall’s prototype race truck share most of the major chassis and drivetrain components, including the robust ladder-type frame; the 420-horsepower V-8 and 10-speed automatic transmission; transfer case; front and rear differentials; plus the front and transfer case skid plates, says Chevy. (See below for more info on Hall’s racing success in this truck.)

We sampled a number of the truck’s technologies during our day-long drive, checking the boxes for both high-speed desert-running and slow-speed rock crawling. Overall, there was good power on tap with plenty of torque to move the half-ton’s 5,800-pound mass, smooth shifts from the 10-speed transmission, good brakes to slow our momentum when needed, and a comfortable ride- even over rugged roads and washboard.

I was excited to experience the ZR2’s talents on some isolated backcountry roads including the Old Dale and Black Eagle Mine Roads 4WD trail, where posted signage warned “Proceed at your own risk: Deep sand and rocks-- stranded drivers have died from heat exposure on park roads.” Truth is, this is just the kind of picturesque and formidable place that 4WD enthusiasts love to explore with a truck that can take you there—and bring you back safely.

2022 Chevrolet Silverado ZR2Chev updated the Silverado's interior with better tech and upscale luxury features.Chevrolet

What makes the ZR2 with its rear leaf-spring set-up abona-fide off-roader? In front are tow hooks and a skid plate underneath the high-mounted steel front bumper, with a 31.8-degree approach angle. Other numbers of note are the: 23.4 breakover angle; 23.3 departure angle; 11.2 inches of ground clearance; with 9.84 inches of suspension travel in front and 10.62 inches in the rear. Its width is 81.2 inches, which helps compared to some of its competitors, as it is more “parkable” in many garages and we found it maneuvered well when navigating through narrow sections of rock. Engineers have also repositioned the dual exhaust for added protection.

One of the truck’s top cool new features is the selectable Terrain Mode that allows for one-pedal driving; this cruise-control-like technology is particularly useful for motoring over rocks and up and down steep slopes. To engage, we locked the ZR2 into 4WD Low, set first gear and let the engineering do the driving, using the throttle to increase speed and the brake to decrease speed, when needed. A forward-facing camera provides visibility to the front and sides, as well as to the back which is another great feature for navigating technical terrain.

*Fuel economy estimates sit at 14 mpg in the city, 17 on the highway and 15 combined. the 24-gallon ZR2’s 360-mile range.

**FAST FACT: Chad Hall Racing also helped test the Chevy Colorado ZR2 off-road technologies in competition — and is still going strong with them. The Colorado ZR2 has been racing since 2017 in the Best in The Desert series and is the only truck in its class to have finished every race entered. It has accumulated more than 22,500 miles of racing experience.

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The IIHS may increase the speeds it uses to test advanced driver aids.

Insurance Institute for Highway Safety

The Insurance Institute for Highway Safety (IIHS) recently announced that it is considering changing the speeds it uses to test vehicle-to-vehicle front crash prevention systems. The agency currently tests the systems at 12 and 25 mph, but says that the speeds don't accurately represent the types of crashes the safety tech is meant to prevent.

Front crash preventionwww.youtube.com

Automatic emergency braking (AEB) is designed to notify of a possible collision and help respond with automatic application of braking. Just like a human using the brake pedal, it can stop the car, but higher speeds make it difficult to stop in time. The new tests would be conducted at 35 to 45 mph, which is the range where a large number of rear-end crashes occur. As Automotive News noted, an IIHS study showed 43 percent of rear-end crashes occur at speeds of 45 mph or less, so it's important to have a test that shows how well the tech performs at those levels.

A whopping 85 percent of 2022 vehicles earned a "Superior" rating in the current testing regime, so the IIHS will remove it from 2023 testing and Top Safety Pick award evaluations. Their view is that, since the majority of vehicles meet the criteria, it's no longer an accurate way of evaluating performance. In its place, the agency introduced a night test for automatic emergency braking systems that will begin next year.

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