BBI Autosport, a professional Porsche tuning shop based in California, USA, is taking vehicle modification to new heights with the help of metal 3D printing technology.
Founded in 2005 by Betim Berisha, who previously worked in Porsche’s motorsport division, BBI quickly made a name for itself in the Porsche tuning scene thanks to its extensive racing experience. The shop’s race cars have won multiple titles at the Pikes Peak International Hill Climb. In 2017, Dmitriy Orlov joined as CTO and introduced 3D printing technology to the team, initially for rapid prototyping.
Recently, BBI partnered with AIG (Advanced Innovation Group), an engineering consulting team within 3D Systems, to put metal additive manufacturing into production for aftermarket parts. Through innovative CAD design and reverse engineering with 3D scanning, and then having AIG optimize the designs for additive processes and print the parts, BBI can manufacture complex components that would be difficult or impossible to produce using traditional methods.
Currently, BBI is increasingly using metal 3D printing to produce final, ready-to-install parts such as exhaust pipes and intake manifolds. These parts are made from Inconel, a high-temperature superalloy. Unlike the traditional approach of cutting and welding multiple segments, 3D printing enables one-piece construction, virtually eliminating weld seams, significantly reducing weight, and maintaining stable performance even under repeated red-hot conditions.
Beyond exhaust systems, BBI is also developing 3D-printed suspension components, body parts, and other structures made from composites and metals. This not only optimizes their internal workflow but also substantially improves overall vehicle performance.
Looking ahead, BBI plans to transition from one-off custom modifications to small-batch vehicle production. CTO Orlov notes that additive manufacturing enables on-demand production, freeing the shop from the constraints of tooling and minimum order quantities. This allows them to create optimal parts for high-end cars using high-performance materials without having to produce hundreds or thousands of units at a time.
