engineering

Performance, Race

BBi R&D: 3D Scanning and Reverse Engineering with Creaform and 3D INFOTECH

Garbage in, garbage out as they say. Reverse engineering is part of every day development at BBi Autosport when creating new performance upgrades or bespoke components. Speed, accuracy and simplicity is key when it comes to gathering data as this helps shorten the development cycle and increase quality. We seek to have OEM like fit and finish with best possible performance possible within every part. For a lot of our development we are using laser scanners to collect data - which allow us to create 3D snapshots of cars and components. This way we do not need to keep referencing the vehicle.

Chris from 3D INFOTECH brought over the latest offering from Creaform - the HandySCAN Black. This is a simple hand-held scanner featuring blue laser technology which performs great on dark and reflective surfaces. The way these scanners collect data is by shining laser beam flashes onto surfaces and using special cameras to capture how the lasers bounce back. Small reflective dots allow the scanner software to create a coordinate system and align all the snapshots together - creating a larger 3D picture. The speed of capture, accuracy has been greatly improved with the HandySCAN Black as it was very impressive how fast it soaked up all the details. What is also very useful is that the objects that are being scanned do not need to be stationary. The 991.2 Carrera T exhaust that we were scanning could be picked up, rotated and moved (as long as the dots are still on) which allowed for much easier and quicker capture.

How that data is handled is just as important as the scanner hardware. Creaform has a great software package that reviews all scanned points, consolidates and optimizes the points and forms a clean, easy to manage file to be used in parametric modelling software.

These scanners allow us to reduce R&D time and reduce dependency on having the vehicle physically in-house for the duration of the development. The 3D snapshots of the parts and car allow us to work within a 3D environment, creating components that would perfectly mesh with the factory parts as needed.

We will update more as we keep developing the Porsche Carrera exhaust system, how we use the data and how our concepts come to life.

 

Performance, Race

Postdating the 964 and 993 : BBi Billet Uprights

Porsche 964 and 993 platforms are still considered quite sophisticated for their time. But time is unforgiving when it comes to technology advances, materials and design. Time simply leaves everything in its dust.

The market has improved support for these cars with hardware, accessories and electronics, but no one thoroughly addressed the outdated suspension geometry. In 2017 we took on bringing the 964/993 platforms up to date using the latest tools and manufacturing processes. Porsche left a lot on the plate in the 90s and we picked up where they left off. To help with this effort we once again partnered with Scarbo Performance who have years of experience developing complex suspension systems and creating incredible parts.

6 Months of Development | 200+ hours of engineering | 4 iterations

We started off with 3D Laser scanning the front suspension of the 964 and 993 platforms, modelling all the components to create a virtual setup of each car in CAD. Furthermore, we scanned the standard OE uprights as well as the EVO variants to evaluate what were were working with.

With the factory configurations set in CAD we started to work on our design targeting what needed to be updated based on how we needed to set the cars. After a complete kinematics study we needed to eliminate bump steer, address the ackerman angle and add adjustability. Most of the cars we work with are also lowered which cut into shock travel. We found that the Evo uprights were well designed, but still left room for improvement.

After 6 months of development, with over 200 hours of engineering and after 4 design iterations we locked the design. The end result is a geometry, strength and weight optimized part. It is machined form 6061 billet aluminum on 5-axis CNC machines and hard coat anodized in black.

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The roll center has been corrected and bump steer has been virtually eliminated. The shock mount was also lowered by 50mm, accommodating lowered vehicles and gaining back shock travel. We have retained full compatibility with OE heat shielding, sensors and bearings. The caliper mounts are designed for the OEM Porsche 993 Brembo units.

The whole upright is not just optimized for suspension geometry but for strength and weight. To ensure best performance on track, the part was subject to extensive FEA testing to be 2x stronger than the OE part. We’ve added structural ribbing to increase rigidity. It has also been optimized for weight. Each upright is just 5.56lbs despite the added strength and denser material.

Bump Steer Curves

The goal is to have no change in steering angle, as the wheels travels up and down (a flat line). The Evo uprights are a significant improvement over OE, but we found further improvement there with the BBi units.
  • Developed for lower ride height: 50mm lower than OEM, non RS

  • Adjusted Strut mount location for full shock travel

  • Corrected Roll Center

  • Virtually eliminated Bump Steer

  • Perfect Ackerman

  • Retains OE Shield Mounting

  • Reinforced Tie Rod and Control Arm mounting

  • FEA Tested for strength vs. weight optimization (2x Stronger, 5.56lbs/pc)

  • 6061-T6 Aluminum with Steel Tapered Inserts

  • 5-Axis CNC Machined

We are very satisfied with the part and the impact it has on these older platforms. Combined with our spherical control arm joints, inner and outer tie rods and a solid coil over setup - it really transforms the car as a whole. We have sold over 50 sets now since the product launched. Francis was one of our first customers with the setup. He tracks and daily drives his car.

"Huge Difference - turn-in is much more immediate, no more on-center wiggle/sloppiness, the weight through the wheel loads up in a nice way now, and that bump steer is no more! The wheel carriers were installed with the tie rods and ball joints from you guys as well. Amazing package!" - Francis

These BBi 964/993 Uprights are available to order as well as the supporting components. We can pre-assemble bearing and help you spec the ideal suspension configuration for your aircooled Porsche.


 

Performance, Race

BBi in the SpeedHunters' Crosshairs

The BBi guys were participating in some local track days and Trevor was the photographer on duty. Started to chat cars and the Porsche world seemed to pique his interest. Next time Trevor was in town we got together, talked shop, talked builds and he snapped some photos while at it.

Trevor is one of the regular contributors at SpeedHunters where he applies his eye for a well framed shot along with a bit of geeking out with his background in mechanical engineering. It was an absolute pleasure talking to Trevor and we are honored to have BBi profiled by SpeedHunters. We look forward to having him back for some progress updates on the builds and do some deep dives into whys, hows and whats behind each project.

For the time being - head over to SpeedHunters and check out our shop.

http://www.speedhunters.com/2019/01/hunting-huntington-beach-inside-bbi-autosport/

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Performance, Race

BBi 997.2/991 DFI Intake Manifold Assembly

Rendering in Fusion360

Rendering in Fusion360

PN#: bbi.991.107.0005    

BBi has developed a comprehensive program for Porsche 997 and 991 DFI Turbo vehicles with full engine builds, big turbo systems with inconel manifolds, methanol injection systems, cooling upgrades and calibration. With every milestone we would develop new products and push the boundaries.

As the horsepower numbers climbed and as the need for E85 came around we had reached the fueling limit of the Porsche 997.2 and 991 Turbo DFI engines and needed a solution. Accommodating 6 more injectors required an intake manifold overhaul which presented an opportunity to resolve more bottlenecks.

997.2 and 991 9A1 engines were digitized with a Faro Edge CMM/Laser scanner and fully mapped. Porsche is very efficient with parts and engineering and we sought to do the same with this information to create components that are cross compatible. Processed data was then imported into Autodesk’s Fusion360 and overlaid.

IPD, a BBi partner, offers a line of plenums for the 997 and 991 platforms, and one in particular for the 997.1 Turbo, which features a large 82mm throttle body upgrade. We were able to evaluate the spacial constraints and incorporate the larger plenum into the design of the manifolds. As a result we are able to run the larger throttle body, gain volume and remove the restriction of the smaller OE DFI plenum. Having all components made of aluminum ensures reliability under high boost as well. The IPD plenum is modified to use Wiggins clamps instead of silicone hoses for maximum reliability and ease of installation.

Fuel injectors were modeled with the spray pattern and placed strategically within the runners, aimed directly at the back of the valves. The positioning ensures proper fuel atomization along with ample clearance for fuel rails, hardware and fuel lines.

The end result is an intake manifold configuration that has more volume, more fueling and more reliability for high boost applications.

The initial design was machined in house and validated on both a 997.2 and a 1200whp 991 turbo running 189 mph in the 1/2 mile with the capacity to hit 207mph. The system can support well over 1500whp with the right turbo sizing.

BBi has partnered with Pankl Racing Systems in to explore mass market applications for additive manufacturing. These low production volume, complex manifolds were the perfect product to leverage the high efficiency of metal 3D printing. The production units are 3D printed in aluminum and finish machined to ensure precision fitment and quality.

Engineering

  • 3D Scanned and CAD designed, Simulated

  • Optimized for 3D printing process

  • 6061-T6 Aluminum manifold and Fuel rails

  • 3D printed, CNC machined

 Features

  • CAD designed for volume, additional fueling and flow

  • Multi-Platform compatibility (plug and play for 997.2 and 991 Turbo Engines)

  • 6 additional injector ports so supplemental fueling

  • CNC machined fuel rails and mounting

  • Wiggins connections to plenum

  • Utilizes high volume IPD plenum

  • Utilizes larger 82mm throttle body