SO, WHAT IS AN ULTRA CAR?

What if… someone told you, that there was a vehicle built with technology of the future, made with a 3D printer, using materials from aerospace technology applied for the first time in a car?

What ifWhat if…… What if…..

Words cannot describe the emotions and the adrenaline rush that this masterpiece of technology elicits in its driver.
It is not just a car, it is the epitome of the future, the next step in automotive evolution, a work of art, a masterpiece.

It is the first Ultra car proudly made in Greece, the country where culture originated, and the future is born.

PRIORITY LIST

ULTRACAR COSMOGONY

ESTIMATED PERFORMANCE

MAX POWER

2.048,7hp (1527.7kw)

TOP SPEED

>+500km/h (>+310mph)

POWER TO WEIGHT RATIO

2,05

MAX TORQUE

1.389,4Nm (1024.7ftlb)

RED LINE

10.000rpm – 11.000rpm

DIMENSION

LENGTH

5.053mm (198.93in)

WIDTH

2.068mm (81.417in)

HEIGHT

1.121mm (44.133in)

WHEELBASE

2.854mm (112,362in)

WEIGHT

1.388kg (2839.55lb)

ACCELERATION

0-100 KM/H (0-62mph)

< 1,9sec

100-200km/h (62-124mph)

< 2,7sec

160-241km/h (100-150mph)

< 2,3sec

0-300kph (0-186,41mph)

< 7,9sec

0-402m (1/4mile)

< 8,1sec

MAX POWER

3.064,7hp (2284.9kw)

TOP SPEED

>+500km/h (>+310mph)

POWER TO WEIGHT RATIO

3,06

MAX TORQUE

1.983,5Nm (1462.9ftlb)

RED LINE

11.800rpm – 12.200rpm

DIMENSION

LENGTH

5.053mm (198.93in)

WIDTH

2.068mm (81.417in)

HEIGHT

1.121mm (44.133in)

WHEELBASE

2.854mm (112,362in)

WEIGHT

1.272kg (2804.27lb)

ACCELERATION

0-100 KM/H (0-62mph)

< 1,55sec

100-200km/h (62-124mph)

< 1,7sec

160-241km/h (100-150mph)

< 1,4sec

0-300kph (0-186,41mph)

< 7,1sec

0-402m (1/4mile)

< 7,5sec

DETAILS

FINGERPRINT RECOGNITION

3D PRINTED
WHEELS

AUGUMENTED
REALITY UI

AERODYNAMIC FENDER

ZYLON

TURBO CARBON

TITANIUM WISHBONE

3D PRINTED MAGNESIUM WHEELS AND BRAKES

ENGINE

Type V10 90 degrees
Billet aluminum engine block 7 axis point milled.

Displacement: 3.955,8 cm3

Max power: 2.048,7hp (1527.7kw)

Max torque: 1.389,4Nm (1024.7ftlb)

Red line: 10.000 – 11.000rpm (depends on the final engine and fuel set up)

Mean piston Velocity: 27,1 m/s

Instantaneous piston Velocity: 32,5 m/s

Max. piston velocity: 43,83 m/s

Max. piston acceleration (@TDC): 60.892 m/s2

Max. piston acceleration (@TDC): 6.207,1 G’s

Instantaneous acceleration: 39.658 m/s2

Instantaneous acceleration: 4,042,6 G’s

Lubrification: Dry Sump

Type V10 90 degrees
3D printed Magnesium alloy engine block.

Displacement: 3.955,8 cm3

Max power: 3.064,7hp (2284.9kw)

Max torque: 1.983,5Nm (1462.9ftlb)

Red line: 11.800rpm – 12.200rpm (depends on the final engine and fuel setup)

Mean piston Velocity: 29,6 m/s

Instantaneous piston Velocity: 35,45 m/s

Max. piston velocity: 47,82 m/s

Max. piston acceleration (@TDC): 72.466 m/s2

Max. piston acceleration (@TDC): 7.386,9 G’s

Instantaneous acceleration: 47.196 m/s2

Instantaneous acceleration: 4.811,0 G’s

Lubrification: Dry Sump

DETAILS

PISTONS

Billet 7 axis point milled X design billet Tennalumsuper alloy
Ultra-strength – Ultimate alloy (683Mpa yield strength), has the highest mechanical strength of all commercially available aluminum alloys (2.5 times stronger than 6061, and 35% stronger than 7075) and exceeds that of many steels. In fact, its yield strength is approaching that of pre-hardened (HRC 26-32) 41XX and 400 series stainless steels but at a third of the weight. In strength-to-weight ratio, Tennalum out performs nearly all other engineering alloys in existence (33% better strength-to-weight performance than 7075, and 28% better performance than 6Al-4V Grade 5 Titanium)

Tennalum super alloy, Sinker EDM
Sinker EDM technique uses an energized shaped electrode in a submerged bath of dielectric fluid to machine conductive metals and offers an efficient manufacturing method to produce complex part details that are difficult to machine by other methods, like 5 axis machines etc. Sinker spark erosion machines are fitted with an Intelligent Speed Power Generator (ISPG) which, using patented technologies, establishes new standards in surface quality, material removal and accuracy of form. Electrode wear is reduced in all machining operations, from roughing to finishing, with copper or graphite electrodes. Productivity shows an average increase of 30 percent, and can even reach 100 percent for pre-milled forms. Even in the presence of deep, narrow cavities, with poor flushing conditions, a 50 percent increase in erosion speed can be obtained with no increase in electrode wear. It appears that the more complex the piston design is, the more high quality of surface.

Titanium 3D printed Anadiaplasi

Stainless Tool Steel H13 3D printed Anadiaplasi (not recommended for this setup)

Billet 7 axis point milled X design billet Tennalumsuper alloy
Ultra-strength – Ultimate alloy (683Mpa yield strength), has the highest mechanical strength of all commercially available aluminum alloys (2.5 times stronger than 6061, and 35% stronger than 7075) and exceeds that of many steels. In fact, its yield strength is approaching that of pre-hardened (HRC 26-32) 41XX and 400 series stainless steels but at a third of the weight. In strength-to-weight ratio, Tennalum out performs nearly all other engineering alloys in existence (33% better strength-to-weight performance than 7075, and 28% better performance than 6Al-4V Grade 5 Titanium)

Tennalum super alloy, Sinker EDM
Sinker EDM technique uses an energized shaped electrode in a submerged bath of dielectric fluid to machine conductive metals and offers an efficient manufacturing method to produce complex part details that are difficult to machine by other methods, like 5 axis machines etc. Sinker spark erosion machines are fitted with an Intelligent Speed Power Generator (ISPG) which, using patented technologies, establishes new standards in surface quality, material removal and accuracy of form. Electrode wear is reduced in all machining operations, from roughing to finishing, with copper or graphite electrodes. Productivity shows an average increase of 30 percent, and can even reach 100 percent for pre-milled forms. Even in the presence of deep, narrow cavities, with poor flushing conditions, a 50 percent increase in erosion speed can be obtained with no increase in electrode wear. It appears that the more complex the piston design is, the more high quality of surface.

Titanium 3D printed Anadiaplasi

Stainless Tool Steel H13 3D printed Anadiaplasi (not recommended for this setup)

Ceramic 3D Nano printed Anadiaplasi zero friction

One of the best weight to compressive Strength ratio on earth, and thermal Conductivity. Can withstand temperatures over 1.500c (2.730F). We print it in NANO to achieve maximum accuracy on tolerances as can’t be machined after production.

Silicon Carbide 3D Nano printed Anadiaplasi
The ultimate compressive strength material of 3.900Mpa and Hardness of 2.800kg/mm2. Can withstand temperatures over 1.650c (3.000F). We print it in NANO to achieve maximum accuracy on tolerances as can’t be machined after production.

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Billet 7 axis point milled X design billet Tennalum super alloy

Tennalum super alloy, Sinker EDM

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Stainless Tool Steel H13 3D printed Anadiaplasi

Stainless Tool Steel H13 3D printed Anadiaplasi

Stainless Tool Steel H13 3D printed Anadiaplasi

Stainless Tool Steel H13 3D printed Anadiaplasi

Ceramic 3D Nano printed Anadiaplasi zero friction

Ceramic 3D Nano printed Anadiaplasi zero friction

Ceramic 3D Nano printed Anadiaplasi zero friction

Ceramic 3D Nano printed Anadiaplasi zero friction

CONRODS

Billet 7 axis point milled pocket designbillet Tennalumsuper alloy
Ultra-strength – Ultimate alloy (683Mpa yield strength), has the highest mechanical strength of all commercially available aluminum alloys (2.5 times stronger than 6061, and 35% stronger than 7075) and exceeds that of many steels. In fact, it’s yield strength is approaching that of pre-hardened (HRC 26-32) 41XX and 400 series stainless steels but at a third of the weight. In strength-to-weight ratio, Tennalum out performs nearly all other engineering alloys in existence (33% better strength-to-weight performance than 7075, and 28% better performance than 6Al-4V Grade 5 Titanium)

Titanium 3D printed Anadiaplasi

H13 tool steel 3D printed Anadiaplasi
(not recommended for this setup)

Billet 7 axis point milled pocket designbillet Tennalumsuper alloy
Ultra-strength – Ultimate alloy (683Mpa yield strength), has the highest mechanical strength of all commercially available aluminum alloys (2.5 times stronger than 6061, and 35% stronger than 7075) and exceeds that of many steels. In fact, it’s yield strength is approaching that of pre-hardened (HRC 26-32) 41XX and 400 series stainless steels but at a third of the weight. In strength-to-weight ratio, Tennalum out performs nearly all other engineering alloys in existence (33% better strength-to-weight performance than 7075, and 28% better performance than 6Al-4V Grade 5 Titanium)

Titanium 3D printed Anadiaplasi

H13 tool steel 3D printed Anadiaplasi
(not recommended for this setup)

Carbon Fiber 3D printed Anadiaplasi

Zylon Fiber 3D printed Anadiaplasi

Ceramic 3D Nano printed Anadiaplasi zero friction
One of the best weight to compressive Strength ratio alloy on earth, and thermal Conductivity. Can withstand temperatures over 1.500c (2.730F). We print it in NANO to achieve maximum accuracy on tolerances as can’t be machined after production.

Billet 7 axis point milled pocket design billet Tennalum super alloy

Billet 7 axis point milled pocket design billet Tennalum super alloy

Billet 7 axis point milled pocket design billet Tennalum super alloy

Billet 7 axis point milled pocket design billet Tennalum super alloy

Billet 7 axis point milled pocket design billet Tennalum super alloy

Billet 7 axis point milled pocket design billet Tennalum super alloy

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Carbon Fiber 3D printed Anadiaplasi

Zylon Fiber 3D printed Anadiaplasi

Ceramic 3D Nano printed Anadiaplasi zero friction

Ceramic 3D Nano printed Anadiaplasi zero friction

Ceramic 3D Nano printed Anadiaplasi zero friction

Ceramic 3D Nano printed Anadiaplasi zero friction

CRANKSHAFT

7 axis point milled H13 tool steel

3D printed Anadiaplasi H13 tool steel

7 axis point milled H13 tool steel

3D printed Anadiaplasi H13 tool steel

3D printed Anadiaplasi Titanium Alloy

3D printed Anadiaplasi H13 tool steel

3D printed Anadiaplasi H13 tool steel

3D printed Anadiaplasi H13 tool steel

3D printed Anadiaplasi H13 tool steel

3D printed Anadiaplasi Titanium Alloy

3D printed Anadiaplasi Titanium Alloy

3D printed Anadiaplasi Titanium Alloy

3D printed Anadiaplasi Titanium Alloy

3D printed Anadiaplasi Titanium Alloy

CYLINDER HEAD

7 axis point milled billet aluminum

40 valves – Inconel 751 hollow sodium filled valves or Titanium

7 axis point milled hollow H13 steel camshafts 4.16G Ramp Rate valve acceleration or
7 axis point milled hollow Titanium camshafts 4.32G Ramp Rate valve acceleration

Beryllium valve seats

11.000rpm @ 183,3Hz

Intake velocity: 0,45 Mach

Exhaust Velocity: 0,64 Mach

7 axis point milled billet aluminum or 3D printed magnesium alloy

40 valves – Inconel 751 hollow sodium filled valves or Titanium (recommended)

7 axis point milled hollow H13 steel camshafts 4,82G Ramp Rate valve acceleration or 7 axis point milled hollow Titanium camshafts 5,13G Ramp Rate valve acceleration

Beryllium valve seats

12.200rpm @ 203,3Hz

Intake velocity: 0,52 Mach

Exhaust Velocity: 0,64 Mach

TURBOCHARGERS

2 x total 214lbs/min air flow

Billet aluminum 7 axis point milled compressor cover, 7 axis point milled compressor wheel billet Tennalum alloy gen2 high flow design, 7 axis billet point milled turbine wheel one piece.
Double ceramic ball bearing CHRA.

Turbine wheel 7 axis billet point milled Inconel 713c one piece and 7 axis
Mar-M246 one piece, 3D printed Magnesium compressor cover

2 x total 312lbs/min air flow

Billet aluminum 7 axis point milled compressor cover, 7 axis point milled compressor wheel billet Tennalum alloy gen2 high flow design, Inconel 713c 7 axis billet point milled one piece turbine wheel or billet 7 axis point milled Mar-M246 one piece. Double ceramic ball bearing CHRA.

Carbon Fiber Compressor Cover
3D printed Magnesium Compressor cover
Carbon Fiber compressor wheel gen2 high flow design
Ultra-low inertia Titanium Aluminide 7 axis billet point milled one piece turbine wheel or 3D printed Titanium Aluminide
Double ceramic ball bearing CHRA 3D printed Titanium Aluminide

FUEL SETUP

10 x Direct Port & 10 x Port fuel injectors

TRANSMISSION

Electronically controlled all-wheels drive

GEARBOX

Dual clutch 7 or 8 speed

BODY & CHASSIS

Chassis: Monocoque Zylon

Poly (p-phenylene-2,6-benzobisoxazole), is the ultimate material, the world’s strongest man-made fiber. It is also the first organic fiber whose cross-sectional strength outperforms both steel and carbon fiber.

Body: 78% of the body is Anadiaplasi 3D printed from titanium and magnesium alloys & carbon fiber or carbon Kevlar body parts.

ROOF

Carbon fiber or Amorphous metal dubbed SAM2X5-630

SAM2X5-630 is a new material with an unusual chemical structure that makes it incredibly hard and yet elastic. The material can withstand heavy impacts without deforming – even when pushed beyond its elastic limits, it doesn’t fracture, instead retaining most of its original strength. SAM2X5-630 has the highest elastic limit of any material known. A 1,5-1,8 mm-thick piece of SAM2X5-630 was measured at 11,76 ± 1,26 GPa as stainless steel has an elastic limit of 0,2 GPa. This makes the roof of the car extremely strong to secure the cabin.

AERODYNAMICS

Particular emphasis has been placed on the study and design of aerodynamics, as they are two factors on which we have relied for the construction of the entire car, making it currently the best vehicle after the F1.

At speeds over 500km on track conditions, in order to achieve the ultimate turning time, everything must be perfectly designed and we must exhaust all room for improvement.

The front spoiler gives total downforce 2.780 N and total Drag 408 N and Aerodynamic efficiency: Ci / Cd = 6,813, numbers and proportions that can be found only in F1 cars.

The floor is also innovatively designed, in order to take advantage of the Venturi effect, i.e the difference in pressure and speed of the upper part of the car with the lower one and to minimize the lifting of the car and push it to the ground with greater force in combination with the large diffuser.

The vertical fins under the floor help keep the laminar airflow (air flowing in a smooth path) out the back of the vehicle, without these vertical fins the air can become turbulent (airflow crossing directions). Laminar airflow increases efficiency as turbulent air decreases efficiency by creating drag.

As for the front surface and the way the air is transferred from the front to the back, the design helps so that the air hugs the vehicle and passes almost all through the front of the wings, around the monocoque and comes out into the back airways with a tendency to push the car to the ground. The rear air ducts have airflow Volume / 16.990m3 / HR and are capable of supplying horsepower over 3.000 horsepower.

IINTAKE MANIFOLD

Billet Aluminum 7 axis or Carbon Fiber

EXHAUST MANIFOLD

Inconel 718

Nasa AFRPE-4 MDA-free polyimide carbon fiber

EXHAUST

Titanium or Nasa AFRPE-4 MDA-free polyimide carbon fiber

EXHAUST TIPS

Titanium 3D printed or Inconel 3D printed

STEERING SYSTEM

Electro-mechanical Power Steering

SUSPENSION

Double wishbone fully independent suspension

Braking system / Rotor hubs / Wheel Hubs / Wishbone / Driveshaft

Calipers: 3D printed Anadiaplasi Titanium or Magnesium Matrix composite

Discs: Carbon ceramic ventilated and cross drilled 422mm front & 416mm rear

Rotor hubs: 3D printed Anadiaplasi titanium or magnesium Matrix composite

Wheel Hubs: Titanium 3D printed Anadiaplasi

Wishbone: Titanium or Magnesium 3D printed Anadiaplasi

Driveshaft: Carbon fiber composite (39-55 degrees Helical fibers and Axial fibers setup)

Wheel bearings: Ceramic

Calipers: 3D printed Anadiaplasi Titanium or Magnesium Matrix composite

Discs: Carbon ceramic ventilated and cross drilled 452mm front & 426mm rear

Rotor hubs: 3D printed Anadiaplasi titanium or magnesium Matrix composite

Wheel Hubs: Titanium 3D printed Anadiaplasi

Wishbone: Titanium or Magnesium 3D printed Anadiaplasi

Driveshaft: Carbon fiber composite (39-55 degrees Helical fibers and Axial fibers setup)

Wheel bearings: Ceramic

Carbon ceramic ventilated and cross drilled 482mm x 42mm front & 442mm x 40mm rear

Carbon ceramic ventilated and cross drilled 482mm x 42mm front & 442mm x 40mm rear

Carbon ceramic ventilated and cross drilled 482mm x 42mm front & 442mm x 40mm rear

Carbon fiber / Kevlar composite (39-55 degrees Helical fibers and Axial fibers setup) with Titanium Joins

Carbon fiber / Kevlar composite (39-55 degrees Helical fibers and Axial fibers setup) with Titanium Joins

3D printed Anadiaplasi titanium or magnesium Matrix composite

Titanium 3D printed Anadiaplasi

Titanium 3D printed Anadiaplasi

Titanium or Magnesium 3D printed Anadiaplasi

Titanium or Magnesium 3D printed Anadiaplasi

WHEELS

Front rims: 7 axis point milled billet Tennalum super alloy 21’’ x 9’’

3D printed Anadiaplasi Magnesium Alloy

Rear rims: 7 axis point milled billet Tennalum super alloy 22’’ x 13’’

Titanium 3D printed Anadiaplasi

INTERIOR

2 built in to the monocoque Seats Carbon fiber and Zylon with Alcantara, for lower center of gravity and perfect Roll and Pitch setup (Roll = The angle between the car’s body and a longitudinal axis. Roll is caused by centrifugal forces and “uneven” track surfaces.) – (Pitch – The angle between the car’s body and a transverse axis. Pitch is caused by the car’s acceleration or deceleration. It is most noticeable under heavy braking, with the car tending to angle forward.

3D printed Anadiaplasi titanium steering wheel, 3D printed Anadiaplasi titanium pedals, 3D printed Anadiaplasi titanium rear-view mirror with 2 x built in cameras, magnesium 3D printed steering wheel column box

Zylon boor panels, zylon car dashboard with Alcantara

AUGUMENTED
REALITY UI

ELECTRONICS

5G connection to server / Live tune protocol

5G capabilities of car to car, car to road, and car to pedestrian communication would play an important role in getting us safely from A to B so fast.

2 x Camera’s face and facial expression recognition built in rear mirror

Voice commands

Steering wheel smart features:

A healthcare app to regularly monitor the health of driver such as the stress levels. If a driver is under too much stress, the car will adjust its power, the steering wheel and traction control system. Each driver-profile-user can adjust his own strategy.

Augmented Reality

VR glasses

Invisible to Visible technology

Fingertip driver recognition