BBi Additive : additive manufacturing | Powered by Pankl

Additive manufacturing (AM) is a method of production where physical objects are created by adding material, building up and using just the needed amount to create the intended part. This is the industrial revolution of our time and as this manufacturing technology evolves it will open doors for more creative engineering, more efficient production, better solutions and reduction of waste. BBi has always sought to be on the forefront of innovation, applying technology creatively to solve problems, expand applications and push performance.

Pankl Racing Systems, a name that is synonymous with motorsport innovation and advanced technologies, is partnering with BBi Autosport to advance additive manufacturing. BBi has already used 3D metal printing across various projects and its boutique product line and market presence is well positioned to leverage the advantages of AM.


What better way to define a manufacturing process other than by a school of through focused on efficiency, purpose and impact. Dieter Rams, a German industrial designer and the inspiration for most current products, created a set of rules, principles that he felt should define good design. These principles, no doubt, have influenced BBi’s standards and can clearly be observed within Porsche’s own design language. These guidelines call for a certain level of efficiency, tidiness, consideration and responsibility - all elements that are reflected within additive manufacturing.

AM (21).JPG

Good design is innovative

3D printing breaks us free from conventional manufacturing processes. Designers and engineers are free to explore components which are more functional, reduce assembly complexity, and more flexible and free from tooling constraints or inefficient material usage. And this is just the beginning.

AM (21).JPG

Good design makes a product useful

Current mass production processes force engineers to break components into smaller parts as there are limitations on machining, casting and forming. Additive manufacturing helps solve that by allowing for consolidation of geometry and design needs into singular components.

Good design is aesthetic

With 3D printing the contour and curvature options are virtually unlimited. Intricate surfaces, tight radii, overhangs can be possible as well as much thinner walls and more delicate features. Additive further bridges the gap between form and function.

AM (21).JPG

Good design is


The current printing technology, be it plastic or metal can create components just as strong as machined, cast or moulded parts and do so more efficiently. BBi inconel turbo headers, printed to tolerances impossible to achieve with investment casting, withstand the harshest conditions when used to generate over 1200 horsepower. The printing process allows us to use the material to its fullest capacity of managing heat and maintaining strength.

Good design is environmentally friendly

Simple: only use what is needed. With 3D printing there is virtual no waste, no need for extensive tooling. This is especially helpful for complex pieces or small volume production. The higher cost of the process (for now) is offset by minimal need for extra resources or energy.

Good design is as little design
as possible

Less, but Better. This phrase really defines additive manufacturing which achieves the superior functionality, optimal material properties and provides expanded design opportunities.