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The Ford Mustang GTD utilized 3D-printed critical aerodynamic components to break the 7-minute barrier at the Nürburgring Nordschleife.

September 23, 2025 Applications 218

Ford Motor Company, during the development of the 2025 Mustang GTD, utilized 3D printing technology to manufacture critical aerodynamic components.

Ford 2025 Mustang GTD

Ford Motor Company, during the development of the 2025 Mustang GTD, utilized 3D printing technology to manufacture critical aerodynamic components. This contributed to the model's breakthrough sub-7-minute lap time on the Nürburgring Nordschleife, making it the first production American vehicle to achieve this milestone. This accomplishment underscores the significant role of additive manufacturing in the development of high-performance vehicles and aerodynamic optimization.

The use of 3D-printed small critical components has transformed aerodynamic tuning.

As a supercar that is "road-legal and track-ready," the Mustang GTD is equipped with a 5.2-liter supercharged V8 engine and extensively utilizes a carbon fiber body to reduce weight. The vehicle can be regarded as the road-legal version of the GT3 race car, featuring an aggressive exterior design with exaggerated wide-body kits and multiple exclusive aerodynamic components. The interior has also undergone a comprehensive track-focused redesign, creating a stark contrast with the standard version. This production model is expected to deliver a power output exceeding 800 horsepower.

The 2025 Mustang GTD achieved a crucial breakthrough in its lap time by integrating small aerodynamic components called "hood strakes" around the hood vent.

Ford's Chief Program Engineer, Greg Goodall, detailed how the team utilized 3D printing technology at Germany's Nürburgring circuit to optimize aerodynamic design, significantly improving lap time performance. The R&D team rapidly iterated on "hood strakes"—an aerodynamic component installed around the hood vent, resembling a ski slope—using 3D printing. These parts effectively increase downforce, optimizing the vehicle's high-speed stability and grip.

The "hood strakes" project was jointly initiated by Goodall and GTD Vehicle Dynamics Technical Specialist, Steve Thompson, with on-track testing conducted at the Nürburgring. Thanks to the high flexibility offered by 3D printing, the team completed approximately eight design iterations and multiple drag coefficient tests within a few weeks. The final 3D-printed hood strakes were integrated into the existing body structure via an adhesive bonding process, achieving a notable enhancement in aerodynamic performance.

Goodall stated, "Without 3D printing technology, it would have been very difficult to achieve this level of design optimization and make this historic lap time breakthrough in such a short timeframe."

Aerodynamic kit developed using 3D printing technology.

Ford's On-Demand 3D Printing Technology

As a pioneer in 3D printing technology, Ford has long implemented additive manufacturing in prototyping, functional validation, and end-part production. Currently, Ford's Michigan Assembly Plant mass-produces 3D-printed components including HVAC lever arms, auxiliary plugs, and electric parking brake brackets. Furthermore, 3D printing plays a critical role in developing new energy vehicles like the all-electric Explorer, enabling agile manufacturing and rapid prototype validation at Ford's Cologne Plant.

Ford utilizes SLS 3D printing for functional charging port prototypes.

It is worth mentioning that Ford has also applied 3D printing technology in its collaboration with the Oracle Red Bull Racing Formula 1 team, producing over a thousand high-performance metal and polymer components for the team. These parts are developed with extensive reference to aerospace-grade extreme testing standards, meeting the stringent requirements for lightweight design and strength in F1 racing.

The success of the Mustang GTD project signifies that Ford's application of 3D printing has evolved from an auxiliary tool to a core competency driving performance breakthroughs. In the future, more automotive manufacturers will extend this technological advantage from elite motorsports to large-scale electric vehicle manufacturing, thereby defining a new paradigm for high-performance automotive R&D and smart manufacturing.