Rapid Prototype Blog

Natalie Anderson asked:



Last week, Volkswagen Group’s SEAT Spanish subsidiary unveiled a new stunning concept vehicle at the company’s stand in the 77th annual Geneva International Motor Show. The SEAT Altea Freetrack Prototype made its word premiere at the Geneva show and stirred the European crowd with its aggressive 4×4 body styling along with the concept vehicle’s technical innovations and sporty features.

According to the Spanish automaker: “The Altea Freetrack Prototype has an aggressive look which is fully in keeping with its adventurous character, along with sporty and dynamic lines, to reflect the character of the Spanish brand. Every detail of its interior exudes luxury. Thanks to both the design and materials used, the Freetrack Prototype is ready to offer passengers a first-class journey.” Moreover the company also said the Altea Freetrack Prototype shows off features that mark the starting point of the next-generation SEAT SUV models.

The concept vehicle’s front fascia showcases a smooth exclusive bumper with hexagonal grille air intakes. Moreover, the Altea Freetrack Prototype is also equipped with LED fog lights with aluminium casings, bi-xenon headlights with AFS technology, two triangular-shaped tailpipes integrated into the rear bumper, and 19-inch spoke wheels

On the inside, the Altea Freetrack Prototype features a 2+2 seating layout with bucket seats resembling those seats found in sports cars. This feature adds up to the sporty styling of the concept vehicle. The interior also offers two-tone brown and white leather upholstery and panoramic roof. The instrument panel features two dials located on the right-hand side and a multi-function screen to the left. On the center console, two screens provides driving information in the upper section, including data for off-road driving, and air conditioning information in the lower section. Exclusive design for the concept vehicle includes the air diffusers with vertical layout on the centre console and a circular design on the sides.

As expected for an SUV model, the Altea Freetrack Prototype has a wide boot and luggage space. A new panel on the guiding wire is available to hold the stuff in place. Other interior features include luggage rack, and rear window integrated aerial.

Moving on the technical side, the Altea Freetrack Prototype comes with a 2.0 TFSI engine under its hood. The engine is coupled with a six-speed manual transmission powering the four wheels through a Haldex-type configuration and an electronically controlled hydro-mechanical connection along with Volkswagen shock. The concept car also comes with SEAT’s Multi Driving Concept (MDC), allowing the vehicle to have the capability to switch from MPV (Multi Purpose Vehicle) mode to all-terrain vehicle mode.

Prototype Tooling

Natalie Anderson asked:


For this year Volkswagen’s SEAT has succeeded in surprising visitors in Geneva with its Altea Freetrack Prototype. Far from being just a concept of mere styling, the Freetrack Prototype has provided a preview of the styling and technological innovations that the Technical Centre in Martorell have been working on.

The Altea Freetrack Prototype has meaner and bolder look which supports its adventurous character. It also has sporty and dynamic lines which reflect the character of the Spanish brand. Everything about the interior of the Freetrack Prototype screams luxury which is attributed to both design and materials used. The Freetrack is a perfect ride for people who wants first-class journey. And in keeping with the tradition of building quality vehicles, the Altea Freetrack Prototype makes use of only top-of-the-line auto parts supplied by Volkswagen like the popular Volkswagen timing belt which is renowned for quality and durability.

Compared to the Altea XL, the Freetrack Prototype is 185 mm higher which provides it with perfect angles of approach, ramp breakover angle, and departure. All these remarkable features are combined with the Freetrack’s full four-wheel-drive system making it into a genuine off-roader.

The Freetrack Prototype is powered by a 240 hp 2.0 TFSI engine and six-speed manual gearbox which means that this vehicle not only have a sporty look but in fact an authentic sporty 4×4 in its own right. The interior of the Freetrack models a 2+2 layout with racing style bucket seats. There is also a practical and highly functional storage area located between the rear seats.

The Freetrack Prototype embodies the conclusion of SEAT’s Multi Driving Concept (MDC) which was initially launched four years ago with the Salsa concept car which was later consolidated with the Salsa Emocion— both had their origins in the new generation of the SEAT models. This concept promotes the traditional MPV (Multi Purpose Vehicle) which SEAT models are predominantly well known of aside from characteristics such as interior versatility and spaciousness that satisfies every demand of car buyers.

The Freetrack Prototype just like the Salsa concept car is a vehicle that is ideal for non-conformists who are always looking for that extra something in vehicles. And with the Multi Driving Concept integrated in the Freetrack Prototype car buyers are given more option in the 4×4 segment.

Fused Deposition Modeling

Zeke Gervis asked:


Pontiac Daytona Prototype (DP) and GT teams are preparing for the second distance race of the season—the Sahlen’s Six hours at the Glen and the round six of the Grand-Am Rolex Sports Car Series presented by Crown Royal Special Reserve which will be run on June 9, 2007, Saturday.

The Watkins Glen International raceway is considered to be historic with a 3.4-mile layout and 11 turns, it the third longest race on the Rolex Series schedule. The six-hour race will feature both GT and DP cars racing together for the first time in Mexico City.

With the DP, Pontiac the maker of high quality Pontiac oxygen sensor has been able to maintain a perfect pole qualifying streak for 2007. The top starting position has been dominated by Pontiac power, three teams, and four drivers. Colin Braun driving the No. 75 Krohn Racing Pontiac Riley has taken the pole in Mexico City and also at Virginia International Raceway.

Jan Magnussen driver of the No. 10 Sun Trust entry has obtained the top spot at Homestead. Alex Gurney and Jon Fogarty in the GAINSCO Pontiac have gotten two point starts to their credit, one at the Rolex 24 while the second at Laguna Seca.

Gurney and Fogarty are hoping to get their second win on the season with the first coming at Mexico City. The California duo have been heading the field all season and consistently qualifying at either first or second in every race so far.

The No.10 SunTrust Wayne Taylor Racing team will have a new driver to join the fold at the Glen. Jonathan Cochet is a Frenchman and will share duties with seasoned veteran Max Angelelli. Cochet will contribute a wealth of open-wheel experience as well as some DP driving miles to the SunTrust camp for this weekend’s race.

Currently the Khron Racing team is the defending six-hour winners from last year. Colin Braun was not able to participate last year since the track includes cigarette marketing contracts and prohibited minor drivers from joining the race. But Braun is now 18 years old and with Pontiac power and teammate Max Papis, the youngster believes that they have better chance to win this season.

The No.91 Riley-Mathews Motorsports Pontiac Riley that was driven by Jim Mathews and Marc Goosens is looking to be a factor in the race this weekend. The duo has improved tremendously with every race that they have joined and are now eyeing for a top finish.

For the No. 06 Pontiac GXP.R, Andy Pilgrim will join Tim Lewis Jr. and Leighton Reese at the Glen. All three drivers are fresh from a win last week with Reese and Lewis Jr. victorious at Lime Rock while Pilgrim won at Charlotte in Cadillac CTSV World Challenge car.

Paul Edwards and Kelly Collins currently sit third in the GT driver point standings. The duo has been fast all year and has led significant laps in the last two events at Lime Rock and Laguna Seca. They will bring the No. 07 Banner Pontiac GXP.R to the Glen and hopes to obtain their first win on the season.

The Six Hours of the Glen will start on Saturday, June 9 at 11:00 AM and will be televised on SPEED Channel in two segments. The first segment will start at 11:00 AM EDT while the second part will rejoin the action at 2:30 PM until the finish of the race.

Reverse Engineering

Correy Putton asked:



PML Flightlink, the small British electrical-engineering company, made the Mini Cooper a real shocker. The magic recipe is called the “pancake.” No, not the tempting thing you crave for because of its succulent maple syrup and butter icing on top. “Pancake” is composed of brushless electric motors that produce a shocking 640 units of horsepower.

Flat “pancake” is PML’s specialty. The company makes them for various purposes – marine, military and construction to name but a few. These motors are mated to the Mini Cooper’s 19-inch wheels to make it an electrifying Mini. Each wheel contains a similar motor – each rated at 160 horsepower. Hence, an all-wheel-drive is capable of producing 640 horsepower. Top speed of the car is estimated to be over 150 mph, with the capacity to accelerate from 0 to 60 huge ones in just 4.5 seconds.

The electrifying version of Cooper was earlier showcased by the automaker at the British International Motor Show and at the Electric Vehicle Symposium in Japan. “We’ve sort of reinvented the wheel,” said Chris Newman of PML Flightlink. In comparison with the standard Mini Cooper auto parts, the reinvented version comes with protruding oversized wheels. It is also those wheels that give a prominent distinction to the prototype from all other electric and hybrid cars available these days.

The hub motor is nothing new to the automotive realm however; PML claims that its motors have the most excellent power-to-ratio in the industry. PML’s motor unit with the miniature Hi-Pa drive inverter weighs 53 pounds. Moreover, the complete wheel assembly including the tire is only 4.4 pounds heavier than a standard Mini. As a result, the unsprung weight is small.

To produce the prototype Mini, PML starts with a new Cooper, removes the engine, the brakes and the transmission. What are found under the hood include the 300-volt lithium polymer battery pack and a series of 135 supercapacitors. These auto parts Mini enhance both the electrical and top end power of the prototype.

Each wheel motor requires no transmission or differential. In fact, they are just controlled electrically. Wheel motors also serve as the brakes. They take the car’s kinetic energy and convert it to electrical energy. At this point, PML has not developed yet a mechanical backup brake system.

Under the rear floor is a 250cc twin-cylinder four-stroke gasoline kart engine that could run at stable speed to recharge the batteries. The automaker claims fuel consumption to be approximately 65 mpg. The electric power of the prototype is expected to last about four to five at an average speed of 50 mph before the gas-powered generator fires up to refill the batteries. In addition, the batteries could also be charged from a household electrical supply. This is intended by PML to preclude avoidable inconvenience.

Unfortunately, the 640 horsepower Mini Cooper prototype is just aimed at catching interest of car aficionados. Moreover, those who want to get hold of the car may find it hard to own one. The prototype Mini is priced at $350,000 – more or less. Also, the motors are and casings are handmade. However, according to PML, mass-producing the motors and control systems could cut the price significantly. Also, if the prototype version is to be mass produced, only 2 of the potent motors would be sufficient in most applications. PML is looking forward to joint ventures with automakers and investors in connection with entering electric-car business.

Rotational Molding