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  • Writer's pictureGeorge Tsakonopoulos

From concept to reality - Creating a Twin Turbo kit for the V10 Audi R8.

TPE Precision is an automotive company consists of two divisions.

1) Performance hardware and software. These are TPE Precision products available to order via our website and our authorized dealer network.

2) Product development for other automotive businesses. We support projects from the early stage of product realization and design to engineering and manufacturing.

One of our latest projects, was the development of a twin turbo kit for the

V10 Audi R8 (gen 2).

The project was commissioned to us by Project Factory Motorsport .

They asked us to develop a product in order to expand their brand in the high end R8-Huracan market.

Twin turbo kit Audi R8 V10
Product Development - Twin turbo kit Audi R8 V10

Customer's main objectives: repeatability, plug and play fitment, high quality and maximum efficiency.

In order to achieve the above, there is meticulous engineering involved, expanding to material selection and manufacturing methods.

Everything was made from billet aluminum in a 5 axis cnc machine, even the turbo brackets (see photo below) and the exhaust is made from titanium (The exhaust disserves a separate blog post as it is a work of art; fabricated in house by Project Factory Motorsport).

Twin turbo r8 v10
Billet brackets for the turbos.

In order to have a clear picture of the product in question we 3D Scanned the engine bay and all the related components at Project Factory Motorsport premises.

3D scan, turbo
Detail: 3D Scan file from the Turbo.

In total we did eight 3D Scans.

  • The engine bay with the turbos (placed in the desired place).

  • The engine bay without the turbos.

  • The 2 turbos.

  • Fuel filter.

  • Fuel regulator.

  • Blow of valve.

  • Engine cover.

After capturing all the necessary data, we started assembling all the files in our system.

The assembly of the 3dscan files, gave us a clear understanding of the available space.

Then utilizing CAD (Computer Aided Design), we started the design phase. The utilization of CAD in accordance with the scanned files meant that we could maximize the use of the available space without sacrificing fitment and efficiency.

Engine bay 3dscan.
CAD Model of the charge coolers in the 3D scanned engine bay.

Although the two sides look very similar, there are small differences in the right and left hand side of the engine bay, thus the charge coolers are not mirrored.

Audi R8 twin turbo kit, development.
Left side.
Audi R8 twin turbo kit, development.
Right side.

After the design of the kit was finished, we 3d printed all the components utilizing our inhouse 3dprinters in order to verify fitment. This is actually the point where we were able to make adjustments to the kit to ensure perfect fit. Moreover the test fit of the printed parts verified installation ease, something of paramount importantance for the customer experience.

3d printing
One of printed models.
3d printing, charge coolers test fitment.
First test of the 3d printed assembly. That exhaust ... is a masterpiece.

Once the verification of the 3dprint models was done, we proceeded to DFM (Design for Manufacturing). DFM is driven by budget-cost constrains and the capabilities of the CNC machine that will produce the parts.

The machined parts were painted white to match the vehicles colour.

The result speaks for itself.

Audi R8 v10 Twin turbo kit.
Finished product. Audi R8 v10 Twin turbo kit.

There is an option to colour code the product according customer needs.

Twin turbo kit Audi R8 V10.
Twin turbo kit Audi R8 V10.

Audi R8 twin turbo kit.
Audi R8 twin turbo kit.

There are additional parts that support the turbo kit, from the fueling system to the gearbox and the intakes that we will cover in a later blog post.

If you have a product in mind and you need help in development, don't hesitate to ask us.

We can support you from the concept stage and initial design to testing and manufacturing.

Thanks for reading!

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