When innovation meets history, we get a symphony of modernity wrapped in the essence of a classic. This project embodies the crossroads of passion, technology, and sustainability. We're not merely resurrecting a 30-year-old legend; we're infusing it with a modern heartbeat. Our mission? To retain the soul, feel, look, and driving experience of the iconic Porsche 964 RSR, while crafting it with a tapestry of Carbon fiber and a medley of meticulously 3D printed Onyx components.
Why take on such a monumental task? Because we believe in challenging the boundaries. We're not only making a statement about the prowess of modern engineering; we're showcasing that technology can harmoniously coexist with sustainability. This electrified tribute will retain its legendary performance, reimagined with a conscientious approach to the environment. Every charge, every drive, will draw purely from the benevolent energy of the sun, thanks to our dedicated solar panels.
The pandemic may have introduced hurdles, but it's only bolstered our determination. With Brink Motorsport as our esteemed collaborator, we are fast-tracking towards our vision. Stay tuned, as we accelerate towards our completion goal in early 2024. Dive into this electric odyssey with us, and witness the fusion of past, present, and future.
When restoring and electrifying a vintage beauty like the Porsche 964 RSR, every detail counts. As we pave our way through this journey, our current challenge revolves around integrating the AEM module and the Alpine media system.The confines of the classic dashboard are indeed limited, presenting a challenge that can only be met with innovation. Our solution? Designing a bespoke center console tailored to the Porsche. Situated right ahead of the handbrake, this console will feature buttons dedicated to 'Drive', 'Neutral', 'Park', and other essential controls.
The centerpiece of this console is a meticulously angled section, 3D printed in the environmentally-conscious Addnite Black Velvet. This filament, made from 100% recycled material, brings together recycled EPDM and tire rubber, offering durability and a touch of sustainability. The setup ensures easy access to both dashboards, optimizing driver convenience.
For the purists among our readers, it's worth noting that in this initial rendition, we're sidelining the original instruments. However, rest assured, reincorporating them is on our agenda for future iterations.One of the unsung heroes in this design process is the cable management. Cables will be discreetly channeled within the hollow sections of the 3D printed console, ensuring a clean look without any compromise on functionality.Leveraging a scanned model of the interior has been invaluable. As a designer, this approach provides a more immediate and precise perspective, significantly streamlining the modeling process in Fusion 360.
Stay tuned as we continue to breathe new electric life into this iconic Porsche 964 RSR!
When you think of a classic Porsche 964, it’s not just about the sleek design or the brand's prestige, but also about the unique driving experience it offers. For enthusiasts, it's the weight distribution, the balance, and the roar of the engine – elements that conjure up a nostalgia that's deeply rooted in automotive history.
However, blending modern technology with this classic beauty, while retaining its original charm, is a meticulous balancing act. At the heart of our endeavor with the Porsche EV-RSR project was a singular vision: to fuse the Porsche's classic experience with the advantages of an electric powertrain, without compromising on its legendary weight distribution.
After rigorous simulations and design iterations, the decision to place all the battery packs inside the Brink Motorsport-developed crash box was born out of necessity and innovation. And while this decision transformed the 964 from a 2+2 to a dedicated two-seater, we believe that the enhancements in performance, safety, and driving experience will be the payoff that true Porsche aficionados will appreciate. Especially when considering the limitations of the original rear seats.
Using our 3D printed prototypes, we’ve laid out the foundation for the final engine, gearbox, and battery placements. This process allowed us to visualize, iterate, and perfect the setup before investing in the actual components – a testament to the merging of classic craftsmanship with modern technology.
As we near the finish line, we've sourced the final pieces of this electrified puzzle: the Engine, VCU, charging units, and more. In our upcoming updates, slated for November 2023, we'll provide a detailed insight into weight metrics, distribution, and the intricate engine bay montage.
For now, we leave you with a sneak peek of our reimagined classic: A Porsche 964, breathing new life, yet preserving its iconic heartbeat.
One of the primary challenges in the world of automotive engineering has always been creating robust, durable, and adaptable components that can endure the rigorous demands of the road. But as technology propels us into a new era, we're pioneering innovative approaches that marry tradition with state-of-the-art methodologies. Enter our 3D print farm, equipped with over 20 Markforged Onyx 3D printers, our latest weapons in the war against conventionality.
ONYX, a robust fusion of Nylon and Carbon fiber, has proven to be a game-changer for automotive applications. Its resilience to extreme conditions, be it temperature, pressure, or chemicals, makes it a prime contender in the world of mould-making.
Our experiments with this material have been nothing short of enlightening. Through rigorous tests in autoclave environments, subjecting our moulds to intense heat and pressure, we discerned the optimal infill for our projects. The honeycomb structure, although a classic choice, didn't quite cut it for us. But the triangular infill, at a range of 37-55%, emerged as the champion, perfectly withstanding the demanding conditions.
However, size limitations of the printer bed posed a unique challenge. But we weren't about to be deterred by such a trivial hurdle. The design we've conceptualized for the Porsche's door in Fusion 360 is no small feat. But with innovation and resourcefulness, we've pieced together an impressive mould from eight different parts, each printed simultaneously on different Markforged machines. The end result? A magnificent mould stretching an impressive 1100 mm x 500 mm, primed and ready for its first encounter with prepreg Carbon fiber and later, Bcomp prepreg.
It's awe-inspiring to see the old-world craft of carbon fiber work blend seamlessly with the cutting-edge technology of 3D printing. As we forge ahead, these moulds stand as a testament to the future of automotive manufacturing, promising efficiency, precision, and innovation. So, stay tuned. We're just revving up!
Last night marked a significant milestone in our journey. With skilled hands and precision, we bid farewell to the vintage combustion engine and gearbox, extracting it from its home of decades. As it was hoisted and removed, a striking comparison emerged. Standing next to its streamlined, sleek electric successor, the combustion engine looked like a relic from another age.
The intricacies, complexities, and sheer bulk of the combustion mechanism starkly contrasted with the clean, minimalist design of the electric motor. It’s astonishing to realize that for over a century, we've relied on such a convoluted system. One can't help but wonder: Were we ensnared in a web of familiar comfort, blind to the untapped potential of simpler, more efficient technologies?
Elon Musk and Tesla have undeniably paved the way, igniting a revolution that challenges the automotive status quo. Their daring vision has emboldened enthusiasts and engineers worldwide, including us, to reconsider the norm and explore cleaner, more sustainable alternatives.
The sheer difference in footprint between the two engines is a testament to more than just technological evolution. It's a poignant reminder of the excesses of the past, urging us to tread more mindfully as we race into the future. Yes, the planet might outlive us, but we owe it to future generations to leave a legacy that’s both innovative and conscious.
Welcome to the electrical era — it's time to charge ahead.
In our quest to bring the Porsche 911 EV-RSR vision to life, transitioning from the digital realm to tangible prototypes remains an essential step. For us, everything requires a tangible counterpart during this transformative phase.
Enter our meticulously 3D printed Cascadia engine, a true marvel of modern engineering, rendered in over 30 distinct parts. Complementing this is the BorgWarner gearbox, split into three detailed components. While most elements have been materialized using recycled PLA, certain crucial components benefit from the robust ONYX material printed on our advanced Markforged machines.
As the RSR donor car is gradually relieved of its classic combustion remnants – from its vintage powertrain to the time-tested gears and electronics – our 3D printed proxies are proving invaluable. These stand-ins pave the way for the actual assembly, guiding our design and implementation decisions.
With the impending arrival of the genuine engine by December 2021, these prototypes enable us to forecast, plan, and start crafting the integral components that will form the heart of our electric beast. Our unparalleled printing capacity, boasting a fleet of over 100 printers, ensures we can bring these ambitious prototypes to reality in under a week.
In the seamless blend of old and new, we're crafting a future where the roar of the engine is replaced by the silent hum of progress.
As we embark on the electrifying journey of embedding the 21 battery cells into our beloved Porsche 911 EV-RSR, we're faced with a complex puzzle - a dance between power and weight distribution, as vividly showcased in our 3D visualizations.
Tipping the scales at 210 kilograms for the entirety of the cells, the overarching aim is to strike that perfect balance, retaining the distinct 911 sensation with an ideal weight spread of 62% at the rear and 38% upfront. As we gear up to harness the might of an 823 Volt system, we're looking at a whopping total of 35.7 kW/h. The sheer power at our fingertips? An exhilarating 525 kW!
But, amidst this electrified enthusiasm, emerges a fundamental question, one that will shape our endeavors throughout the summer: Is raw power truly the endgame? By dialing down the horsepower to align with the original RSR's 360 Hp, we could potentially trim our battery count down to 14, shedding 70Kg off our total weight. Is the pursuit of authentic homage perhaps a more worthy aspiration than sheer force?
Our journey is as much about honoring legacy as it is about innovation. Stay tuned as we navigate this intriguing crossroads.
Having captured every contour of the door's internal anatomy through our precise 3D scanning process, the thrilling phase of design and prototyping beckons. These scans, now seamlessly integrated into our Fusion 360 model, serve as the foundational canvas upon which we reimagine the doors of our Porsche 911 EV-RSR.
Function meets finesse as we carefully plot the incorporation of modern elements like speakers, a revamped handle, and an elegant strap, all while ensuring harmony with the car's innate structure. Our debut concept reflects a juxtaposition of past and present – a minimalist Carbon fiber inner design, luminous and streamlined, that pays homage to the classic by reincorporating certain iconic design fragments.
The goal? A door that encapsulates the essence of the original yet is unequivocally futuristic in its appeal.
The metamorphosis of our Porsche 911 EV-RSR advances, as we peel back layers to its core. Our first mission? Tackling the doors. But, instead of a mere disassembly, we've chosen a path paved with digital innovation. Prior to removing the door sides, they undergo a thorough 3D scanning process. This not only provides us with a detailed blueprint in Fusion 360 but also ensures our design retains the car's authentic essence.
By overlaying 2D geometries on the scanned meshes and establishing fresh construction planes, we've meticulously documented every inch of the original architecture. Such precision is pivotal in preserving those subtle nuances, curves, and contours intrinsic to the car's three-decade legacy. As we conjure a modern redesign, these scans ensure that the spirit of the original interior, with its intricate details and unique characteristics, is seamlessly interwoven.