Additively manufactured Ford Mustang exhaust system boosts performance

October 21, 2021

The final design reduced the weight of the system by around 67% (Courtesy Eplus3D)

Eplus3D, Hangzhou, China, reports that it has recently worked on the development of an exhaust system for a Ford Mustang, customising and optimising its performance though the use of metal Additive Manufacturing.

Having been contacted by a car modification company, Eplus3D looked at how AM could be used to customise exhaust components – not only to improve performance, but to adjust the sound that the exhaust system makes. The objective was to be able to make these adjustments lawfully while offering the car enthusiast an alternative to the stock exhaust option.

The auto exhaust pipe for Ford Mustang completed by conventional technology (Courtesy Eplus3D)

The exhaust components where evaluated by Eplus3D, and, in the early stage of the project, Eplus3D’s designers produced a customised 3D model using the Rhino design software. The internal structure of the exhaust pipe was optimised and designed for the AM process, increasing the operation efficiency and reducing its size.

After completing the design, Eplus3D produced a polymer AM model of the exhaust pipe using to test the gas flow and visually communicate the design to the customer, enabling further product improvement where needed.

Eplus3D’s designers produced a customised 3D model using the Rhino design software (Courtesy Eplus3D)
Model for design confirmation and assembling test (Courtesy Eplus3D)

The final design was said to offer a more pleasing, supercar-like sound (as requested by the customer), and reduced the weight of the system by around 67%. The optimised gas flow helped alleviate issues with power loss, often found when exhaust systems are unable to output the exhaust gas effectively at higher speeds.

The optimised exhaust part is reported to be under trials on the customer’s Ford Mustang (Courtesy Eplus3D)

Once the design was confirmed, Eplus3D used a number of its nationwide AM service centers to simultaneously build multiple components on its EP-M260 AM machines, thus shortening the time of delivery. The part is reported to be currently under trial on the Ford Mustang.

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 226-page issue includes articles and reports on:

  • Metal AM in hydraulics: Aidro’s Valeria Tirelli on opportunities, applications, and joining Desktop Metal
  • I want to break free: The journey towards reducing or eliminating support structures
  • Simufact Additive: Accelerating the Metal Binder Jetting workflow with sintering simulation
  • Metal powder characterisation for Additive Manufacturing: Beyond state-of-the-art standards
  • A look at the future: What does the next decade hold for metal Additive Manufacturing?
  • Reducing residual stress with 500°C build chamber preheating for ‘first time right’ PBF-LB
  • Separating metal AM parts from the build plate – an underestimated challenge
  • How X-ray Computed Tomography is helping an AM service bureau to improve predictive-model based qualification
  • > More information

Latest news


    Sign up to our e-newsletter, sent weekly to AM professionals and end-users around the world. We'll also let you know each time a new issue of Metal AM magazine is available.

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:
    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news
    All past issues are available to download in PDF format, in either single page format or as double-page “spreads” for viewing on large monitors. All downloads are free of charge. Go to archive...

    Connect with us

    Visit our social media channels and sign up to our e-newsletter

    Copy link
    Powered by Social Snap