The Ferrari F136 V8 coming from the factory is naturally aspirated. The goal is to create an aftermarket cast exhaust header to support twin turbo charging the F136. The stock headers were laser scanned and imported into Solidworks to reverse engineer critical features required for new design. The entire rear of the car was also scanned to facilitate virtual mechanical mock up. Parametric design of the new headers begins. 3D prints of the proposed header design are sent to the customer for vehicle fitment confirmation. Design is finalized and CAD model is prepared for the investment casting process. Due to low volume demand of this product, patterns are directly 3D printed and used for the investment casting process to eliminate up front tooling costs and allow for rapid integration of updates and improvements based on real world performance without having to reinvest in tooling.

The Ferrari F136 V8 coming from the factory naturally aspirated
The stock headers were laser scanned and imported into Solidworks to extract critical features
Reverse engineering the head flange
Scan of the car to facilitate design and fitment
Parametric design of the new exhaust header for turbo application
Putting every inch of available space to best use
A prototype is 3D printed and shipped to customer for fitment confirmation
Header optimization for turbo fitment
Design complete, CAD model is de-featured and stock added for gates in prep for 3D printing patterns for the investment casting process