Turbo Manifold 3D Printed from Inconel Powder
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Step 1 Chassis Teardown: • Supra Complete Teardow...
Step 2 Roll Cage Fabrication: • 2020 Drift Supra CAD D...
Step 3 Powder Coat Chassis and Intercooler Build: • 2020 Drift Supra Powde...
Step 4 Chassis Dyno: • 2020 Supra Drift Build...
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More drift team videos:
• Front Wheel Drive to RWD Conversion: • Drift Car Build FWD Co...
• 1007 HP dyno pull: • Dyno Toyota Corolla RW...
• 1000 Horsepower Engine Teardown: • 1000 Horsepower 4 Cyli...
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ABOUT PAPADAKIS RACING:
The Papadakis Racing team began drifting in 2004 and is the most winning team in Formula Drift history, earning the 2015 title with driver Fredric Aasbo, as well as backto back championship titles with driver Tanner Foust in 2007 and 2008. The Rockstar Energy Drink / Nexen Tire Toyota Corolla Hatchback is the latest competition build from the Hawthorne, California, based team.
Team owner Stephan Papadakis is a legend of sport compact racing who began building his reputation in the 1990s with the first front-wheel drive, tube-chassis drag car in the U.S. The team earned multiple records and championships in the discipline, turning in elapsed times and trap speeds previously thought unattainable in front-drive drag cars. Papadakis' successes in front-wheel drive were matched by his efforts in rear-wheel drive when he campaigned a Honda Civic that became just the fifth car to join the NHRA's Sport Compact 200 MPH club
For those following the GR Supra build and noticed that we now have a 6 exhaust port cylinder head instead of the 2 port with integrated exhaust manifold: The 2021 GR Supra A91 now has 382 HP and a revised cylinder head with 6 exhaust ports. Once we went with this new cylinder head we needed to make a new turbo header.
382?
hell yeah 6 port head!
So, in your opinion/ threw the testing, would you say the new designed head was a better/more efficient design over the old single port? Been curious about which is more important, the flow or the thermodynamics. In my head (aint no genius, just a car nut) the single port seems to offer better thermo-propertys, but at a loss of peak flow, where the multi-port head would give you better flow, but at a slight loss in the thermo department.. (hope that wasn't confusing 😁)
Still would love to see one your in-depth videos better explaining problems you saw and the other solution you saw other then just gain I'm power.
Thanks for clarification!
The technology is absolutely mind blowing
For sure ...the "old style" fabricated manifold was lovely as well. But the 3D is next level.
@@danielmarshall4587 imagine the impossible to cnc shapes you can incorporate from 3d printing.
Tons of stuff!! The equipment is super expensive though. I think over 300k USD for an entire setup.
@@soufsidemotorsports8418 there's a 3d metal printer for 5k. I'm sure you could make your own, if you were to take the print head
@@NatoriousGamePlay might be a cool little project. Need to get my Arduino skills up
Just walks in like a chad and just spills the good stuff on us
Zestiest comment 😂 pause
I work at the Steel Mill making that Steel powder used for the 3d printer. Cool to see my work being used in a real world application 👍
Cool man! Out if curiosity where is this mill located?
which mill? I ran a few EBM machines for years
Where are you located and where can I buy powdered metals?? Wow just wow!! How.much is a kilo??
Love to see modern engineering practise being used. I have been a CAD designer for many years and the ability to 3D print pieces like this is a game changer. If you have the Solidworks skills you can now design, tune using finite element analysis and make anything you can imagine. That 3d scanner is nerd porn.
Very true except the pulses from the valves and how they affect the flow are really tough in CFD. I am a cswe and taught solidworks for years and designed a few manifolds including a high hp turbo manifold for an infinity v8 and a turbo bike so im not just blowing smoke:) This was a really cool build.
@@TheShift1313 Wow; you must literally have a ~150 IQ. Engineers alone are ~133 ... but CFD? That's some complex math. Turbulent flow, etc. Maybe you should make a YT channel... this video was way better done than is visible ... but if you're new to the video side...there's a YT channel called "This Old Tony" (which is really good) and you can watch his evolution of production skills. He is very, very smart as well ... but, his videos started off modest ... and you can kinda see the logic that goes into his 'genesis' as a content creator. it's worth checking out, as I'm sure content you'd make would be, as well. In fact, he even spends a couple of episodes introducing and explaining solid works, as well. I bet you'd get a kick out of that. :)
@@TheShift1313 Hi! I am Mechanical Engineering student mainly using Solidworks. I am a beginner but would like to have the skills to design these complex parts. Any tips how to begin doing this so I can model these complex parts in the future?
@@haroldramuk1807 hey harold. I have a channel(mainly fusion 360) called Learn Everything About Design. I did a series designing a honda k24 intake for various mfg methods. Are you looking for just modeling or more about tuned pulse design?
That was probably VERY expensive
And didn't really take advantage of the features you can make with an additive manufacturing process.
Could pirate solidworks, then use a open source scanning software with your phone There's no way around the 3d printing part haha
@@owenspalding971 No kidding they basically printed some bent tubes and still had to weld it together. And they didn't appear to be properly finished so have fun with inconel dust in your turbine... 😬
This is put of most folks budget. 3d printing is extremely expensive.
@@lucysmith4242 I would bet the cost of that arm scanner is similar to what the part cost. $10k-$15k? That's a lower end Faro arm.
this is absolutely insane
Is it? Why?
@@jiveturkey9993 dont worry this is over complicated pipework.
@@jhallin5185 because Inconel is a very cool alloy that has possible application in some of the most advanced engineering projects on earth. It can withstand ridiculous temperatures and 3d printing can allow structures to be created that were previously not possible.
@@vighneshkannan7896 I never denied its cool, but cool doesn't make it better. 3d printing is a great technology that doesn't mean everything should be printed, this manifold was 3d printed for clicks and ad revenue not becuase the technology made it better. My initial comment was too the reaction towards the video not against the process of 3d printing metal. This is not "insane" this is just neat that is all.
@@jhallin5185 No one said it was better though.
I always wondered how metal could be 3D printed. I never imagined it was laser fused. Makes sense and that's fascinating. Beautiful welds.
The technology is crazy, but those welding skills really impressed me.
I was actually coming here to say just this
I really enjoy welding inconel
Welds were the reason I looked for this comment too. Incredible ones
I have a hard enough time trying to weld anything. His skills are so beyond what even good welders have.
I'm impressed that Inconel can be 3d printed now!
Crazy
Just about anything can be now
Its been a material in sls printing for awhile now, over 10 years if not 20 to 30. Metal 3d printing hasn't been so mainstream until now however
F1 was doing this 15 years ago. But very impressive that it’s something that is attainable to us mere mortals now.
@Will Weld For Food aerospace... like you run a welding table at the local small airport? Because a 3D printed titanium flexible exhaust nozzle is what's used to adjust trajectory on some satellites so...
Stephen is the OG. I been around since the FWD EK days, the man was an innovator 25 years ago and he still is.
Both of the manifolds produced were works of art
I clicked on this to procrastinate on my SolidWorks final project. I'm feeling extra guilty.
Hopefully you aren't working with thousands of broken sheet bodies like these guys are.
Same thing here man
Beware. Knowing solidworks it might crash in the meantime.
VHjykfUuYu it keeps crashing trying to create a mesh for analysis lol
Glad I'm not the only one 😂
Would you use the printed or fabricated header?
Can we get an update on the head? 6 exhaust Port vs the original 2? Thanks!! Love your videos. I learn so much!!
Seem like it might be pretty far into diminishing returns territory for the price.
I wouldn't of used it that close to an event like that Go with what is proven. Test the 3d printed one this winter. Get some heat cycles in it. Also please film it for us. Maybe a gopro under the hood to record the glowing lol
Both look great. When did the exhaust ports change from 2 too 6?
doesnt it hurt the performance because its so rough inside?
damn, i really love how papa explains stuff! the tone of his voice, the visuals, directions etc!
It could be categorized as Car ASMR
The amount of information this channel puts out is surreal. The knowledge and experience to get to this level is crazy
I love seeing how much aerospace technology is trickling down into racing. Thanks for showing us the best tech outside f1.
A lot of racing technology trickles to aerospace. 3D printed sand casting cores were pioneered by Formula 1 for their blocks (and still use it instead of full billet blocks) and are heavily used in turbine manufacture.
@@mattnsac i guess that is true since the car was before the airplane, so to speak
@Will Weld For Food interesting info none the less, & likely true since their 3D printed header didn't make it on time, but in the future I think humans are likely to be phased out when the tech is quicker, cheaper, and more accurate. like with allot of the automation areas, but i have seen people still being used in factories so you are still likely correct
@Will Weld For Food wow you okay?
The moon missions wouldn't have happened if surfboard builders didn't help NASA with there techniques for get strength from composites.
You always learn a lot with Papadakis videos, the man knows his stuff in and out :D
Next level! I love seeing technology used in this manner
Steph delivery is perfect. Everything in this video gets explained in such a clear and precise way, he's a great teacher.
i see SP, i click like.
i see denmah, i click like.
I see our lord and savior Denham, I click like.
wow here is Matt! :)
I love SP’s videos is so open with his content..... like someone else!!!
Working with this team would be a dream job! Really awesome engineering!
Would be great. I think Cosworth would be the ultimate though.
This was an amazing video! Thanks for sharing all the parts of the process, I’ve learnt so much from this channel
Awesome! you should do a volume comparison of the 3D printed manifold vs. the traditionally made manifold. it was be interesting to see how much weight and volume you save by 3D printing.
wow that hotside clamp design is incredible
yes, i want that engine just because of that
K04-064 uses almost the same design
If you use the exact same material so the thermal expansion properties, dont make it loosen up..????
It's been more common in the aftermarket, im amazed they can align it correctly on the exhaust holes. There is some Audi RS3s running the same design.
Audi been using this design (VW I know, I work for Audi tho) since about 04, direct injection was introduced and we started using this design where the base of the turbo is clamped by the plate, really good for heat distribution as can use a heatsoak material. K04-064 as mentioned.
I love watching this. Makes me feel like I’m in science class every time I watch a video here.
There's a shortage of inconel world wide and this man is just casually 3d printing exhaust manifolds out of it. But jokes aside, the approaches the engineering on display in each episode, especially the use of inexpensive plastic prints to prototype on the fly and verify the CAD.... it's an impressive workflow.
Those welds are impressive. That was skilled work, as was setting all of this up. Great job guys
The technology, craftsmanship, knowledge and performance demonstrated in every single one of your videos is just absolutely insane. It's so awesome to see how much more advanced and technical automotive performance has gotten and how complex these vehicles are getting.
I should probably delete my comment...I am 21 hours too late! You already said exactly what I thought. sorry.
This is probably one of the coolest things I've ever seen
this is THE definition of a perfect video on car engineering! Thx steph!
Love your videos Pap!! My inner nerd thoroughly enjoys the effort that you put into these snapshots of what goes on way behind the scenes.
I love 3d and cars. This the nuttiest thing I seen in a while.
One of those few channels you subscribe before they tell you to subscribe.
Weird to say but I love how clean and fluid your audio is in your videos.
Both of those headers are just gorgeous, and those welds are amazing. Well done guys keep it up.
This dudes the Supra master.. I don’t think people know how hard it is to rebuild engines
Ryan tureck builds ine too,
Is say that's objective. Some people are mechanically inclined and building stuff, repairing stuff just comes easy (edit, should say comes easier. It's def not easy)
@@Bramon83 id argue rebuilding engines the way this man does it harder than some surgeries lol one slightly wrong move or missed small step and you blow the engine up or it fails
@@goler6477 oh I'm by NO means saying it's easy, just that some people just have an almost instinctual ability to understand mechanical things. Like papa
We always want to see more Stephan! Bring us along for more things! Keep it up pioneer 👍🏻
I have yet to watch a single one of your videos that had any parts that made me want to skip through. Thank you for putting in so much time and effort into these!
I'm really excited for this kind of stuff and I'm looking forward to when these tools become more affordable and available on the market for regular consumers. Hobbyists and car enthusiasts especially don't have to spend so much time and money on parts they need if they can just make the parts themselves
This is insane. What a great demonstration of some really cool tech. Thanks for the great videos!
Craziest motor I’ve ever pedaled! So. much. POWER!
Lucky guy! What are the figures?
You guys do extremely amazing stuff there. Love the technology innovation by you guys.
This is one of the most educational and informative videos about automotive Engineering that I have seen. Love this format. I know you always are very technical and give the greatest details.
The 3D metal printing is wild! This is starting to feel like science fiction. Always love the videos.
It's still a little too good to be true and oversold. The strength of 3D printed metal will not match casting, definitely not forging.
Had a FullRace header for the Evo back in the day. Outstanding product.
I’m always impressed with the content of your vids and the work that goes into the cars.
You guys are awesome ! Such an overlooked channel ! Stay safe and bring on the next ones !
I want to see the Inconel header when heat soaked! That should look pretty!
Loooots of colors I’m sure Just wonder how the colors will pattern when compared to stainless tubing
@@flyonbyya I like pretty colors!
Dark grey
When inconel is at the heat limit, it becomes transparent.
Love seeing new technology being utilised to maximise efficiency.
Brilliant. Love seeing your clean methodical shop. No yelling, just watchmaker precision and innovation.
Love the technical content. Thank you very much for taking the time.
That's pretty next-level, great vid as always
This is exactly what I'm going through mechanical engineering to do. Man this is exciting!
It's strange, every one thinks that the internet is inherently low information and bite sized. If there was a video an hour long detailing the 3d priniting process and welding people would love it. A couple psychologists noted that as soon as you let people find their own sources, they study at the level they are capable of. They noted that most people are way smarter than they are given credit for. Btw, every engineer I know is a dink. One argued with me that aluminum evestrough wouldn't expand due to temperature, it was a continuous piece almost forty meters long. I told him that it would change by almost 2" and he ignored what I said because someone gave him a piece of paper with his name on it.
@@timothybayliss6680 Sounds like he slept through physics 4a lol
@@timothybayliss6680 funny I dealt with the same mentality for years steam and heating hot water lines with no expansion joints or loops .Some runs were 1500+ foot. Basically self destruction especially in earthquakes. Job security welding up cracked- fatigued joints. Plus who in their right mind runs HHW inside a data center.lol
Same thing here ^^ Starting my studies next fall. I hope I will be able to survive it 😅. Probably will be a boatload of work, but possible.
@@Marco-vp8wl You’ll be fine bro. Just stick with it.
I have been looking into 3d printed parts for a bike project. It's really cool to see others having the same idea. Solidworks might have a large learning curve but when you know how to use it, it really flows. I subbed, looking forward to more content like this.
These videos are incredible. Awesome watching the builds.
I feel like I need to emphasize how bleeding edge this work is these guys are doing. 3D printing Inconel is just insane. This is rocket science literally.
This is absolutely amazing.
Thank you for sharing your design and development tools! That's a LOT of work and very complicated. Will look forward to more!!!
Your content is so much more advanced than everything else on youtube, please keep going 👌🏻
Vid hit home for me in so many ways. I was a big fabricator of Honda manifolds in the mid 2000's. Full Race was a big inspiration for me to push myself. I worked through self made collector jigs, then fully porting/polishing collectors inside for every manifold I made. I remember meeting Geoff at SEMA in 2010 (iirc) and Bisi, who I exhibited next to at LA Autoshow...was shocked they both were familiar with my work through Honda-tech. This past year I'm getting into 3D printing and design to develop parts for Corvettes, via my channel...I've been out of the industry for 6yrs now and working to get back in. Been followin Papadakis for a LONG time...early 00's of the Honda game...lol. Printing inconel...man, amazing! I have to keep working and find a new groove again.
10 years ago when I was in college someone suggested this same idea and it never happened. I'm so happy that someone finally did it! Would love to see back to back dyno charts.
They have been able to do this for much longer than 10 years.
How could anyone NOT enjoy this! Endless, Stunning capabilities!!!
You did an incredible job describing the whole process, thank you
I actually went on this video to procrastinate from doing my engineering project in solid works 😂
OoOoOoOoOoOWWwwWww
Soon my skills in welding will become obsolete. Now I need to learn how to use solid works and 3D printers. The new age of fabrication is upon us.
Thanks for this video! I've been an engineer using SolidWorks in a traditional manufacturing role for a long time. Seeing the intersection of engineering/technology/cars really spoke to me and helped to open my eyes to possibilities/applications outside of what I see in my day to day. I just signed up for 3Dexperienceworld and am excited to start probing the possibilities of how I can have my passion be my job.
@10:56 I've always been surprised more dyno tire blowouts don't happen. I've seen cars positioned on rollers where the tire distortion was so bad. This ones actually not too bad but still shows the pressure variation across the whole tire. Super cool video showing the future of 3D printing metals and can't wait for the next installment.
"Turbo Manifold 3D Printed from Inconel Powder" Or "How I spent 6 months and $15,000 getting a header"
Simple thing, madly expensive. True face of engineering.
You can go far cheaper with normal casting. But it takes week or two just for forming. Not including some treatment and CNC work.
@@bocahdongo7769 but casting will give a stronger part. Fused scintering is cool, but cracks form and propagate easier.
Bull shit, the number is much larger. Try more like in 6 figures.
@@truantray That's why I mention casting. It's stronger and far cheaper, especially for pressurized manifold. But the casting time is darn long for such a prototype context.
"Hi, im".. pushes like. Say no more Papadakis
I remember i was blown away 6 years ago when koenigsegg started to 3D print their Turbos. and it is good to se it's becoming more affordable as time goes on
Stellar technical/mechanical skills, effort, and video production! l'm blown away! 😉👍
The printed manifold was awesome, but how 'bout that standing wave in the tire as it ran on the dyno? 🤯
That was a little sketchy. I don't really like rolling dynos like this because even having low pressure in one tire affects readings so much.
I noticed that too. Pretty amazing.
I was so amazed at how this 3D metal printer works. Literally my face was :o the entire time Stev was explaining every little detail
Great job mate it nice to see how other people use the tools I work with and with other new tech. I've use sw to produce laser sintered titanium parts and its great to see you working with a different material
As a self-employed engineer that uses Solidworks every day, this makes me incredibly happy. That printer is... a skosh outside my price range however :D For now I'll be sticking with PLA and ABS.
my company rents out printers. maybe you can rent one?
Wait I'm confused? When did you change the head? I thought the head was only a dual port head?
Yeah I was wondering the same thing, he didn't explained when he made the change
Hmmm I am not up with all the different BMW engines, I wonder what model its off?
Toyota/bmw came up with a new style head, they changed it for the 2020/21 model....I don’t remember out of the top of my head why they did it but it was for turbo exhaust efficiency IIRC
@@ivegonemad I see said the blind man... Still though he would usually tell us the difference in set-up and he didn't say anything. Not saying he owes us a response I'm just saying it was pretty confusing to see a different head on there and manifold with out really any context
@@israelcardona5170 this was the first time with the 6 port head on the car. Used it in just the last rounds of competition
That screw on the shop floor in the final dyno run makes me wanna hide under the bed..... Great video love seeing this stuff!
Top level fabrication and workmanship! Thanks for sharing!
you guys always do amazing work, thank you!
i think the hand made header is way better , almost is an “art” to look at 👍👍
Go see how the Saturn V moon rocket engines were made.
this should be flagged as pornographic content... the amount of engineering put in every single inch of that GR Supra is bloody amazing
Didn't they get beaten by a V8 Mustang?
so what
The 3D metal printing is very impressive. I felt like I was watching a Si-Fi movie. Thanks for sharing this.
Never discussed in TV shows and movies like Star Trek and Star Wars, is how replacement components are made 'in space'. (I've been a HD fleet mechanic for the best part of 50 years.) Well, now we know! The money spent on this project is most likely more than I've made in 50 years a fairly well paid fleet mechanic! Beautifully done post gentlemen! THANKS!
Hi, 3D printing specialist here. I wouldn't recommend this for long-term use. 3D printed metal is poorly-characterized and has generally bad fatigue behavior. Yes, there are high-performance applications that use it, but they tend to be very highly engineered, and have frequent maintenance schedules or very short lifespans. As-is, it'll be quite some time before I would recommend commercializing this sort of approach. For people who aren't deep into metallurgy, just think about this as if someone offered you a manifold that they build up out of TIG filler rod. You'd have to trust them a *lot* - and we're not at that stage yet with metal AM.
Thank you for pointing this out. 3D printing the intake is a good application, but I would not expect this exhaust manifold to last long. At the microscopic level, these prints are full of gaps and voids.
E-beam powder bed fusion with a HIP post process can produce material with good fatigue life no?
HIP heat-treatment would help with the fatigue issue, but it gets very expensive for such large parts.
Daniel Defense has had a silencer out for a couple years that is 3D printed from inconel. I have one, its called the "Wave", I've shot thousands of rounds through it without issues.
@@thastinger345 Silencers are not stressed members. Look, just because you've used something that was 3D printed at some point in your life doesn't mean you understand how they work.
When did the exhaust pirt change from 2 to 6
Well the 2021 Supra has the 6 port engine and I'm assuming he got rid of the previous engine since Fred Aasbo had already done many drifting hours on that engine so it was time to use the new engine, plus 6 ports equals more flow
@@exquisiteart6478 yeah I always thought those 2 ports had to be a major choke point at the top end
@@noahkach Yes and no, cause only one cylinder fires at a time
@@ldadol yeah but you have larger pressure losses due to the smaller radii each exhaust runner has to have in order to fit in the head.
it was always six port, they used another piece on the exhaust manifold to turn to a 2 port, imagine it as a cover 6 port with a cover to convert it to a 2 port
Straight futuristic! Keep up the amazing work!
What a beautiful finished piece. Thank you for sharing this outstanding technology.
So are we just gonna ignore the fact that they have a GR Supra head that has 6 exhaust ports or am I missing something?
I came here to comment this. Even looked through his videos to see if I missed something. 🤔
2021 GR Supra come with 6-port head iirc
Rds is right, the 2021 engine has revised parts including the exhaust, it now has a port for each cylinders
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8:43
The educational info this channel offers is awesome,I learn something new everytime I watch!
Both of these Manifolds are... wow. The printed one: It is amazing how far Tech has brought us. But the handmade one... This thing is pure ART!
now tell everyone how much this cost
The development probably more than 100k , only printing the manifold 5-10k maybe more
“We create these things called parts” What is this word “parts” you speak of?
I think he mentionned the word "parts" in the context of Solidworks because the software has the ability to model different "parts" and merge them in an " assembly". Not all 3d software use these methodology.
I smell a wooosh around the corner
You know the old saying.... parts is parts
The 3D printed manifold is amazing to see the process and outcome. Would be great in tight radius situations. The traditional fabricated manifold is also a work of art. Top quality work. Big numbers on the new Supra too..
Amazing job and one of the best producers ever !!!! 💯💯💯💯
That's the deepest dive into the design process i've ever seen, i absolutely love it!! And the supra sounds absolutely RAW!
This is beautiful. Art and science in harmony.
The best and most cutting edge content out there. The brain power involved in this project is amazing.
This is so easily the most incredible build on youtube. No expense spared and all sorts of the latest tech integrated.