Alpine adopts monolithic 3D printed intake system for Alpenglow Hy6 hydrogen engine

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March 1, 2026 Applications 10349

Hybrid additive–subtractive workflow targets seal integrity validated up to 5-bar pressure cycles

CRP Technology and CRP Meccanica worked with Alpine to develop a monolithic intake plenum and manifold system for the Alpenglow Hy6, a hydrogen-powered rolling prototype. The previous design had problems with sealing during testing because the 3D printed plastic parts and glued aluminum edges expanded and vibrated differently at the joints.

Alpine moved to a single-material architecture using SLS with carbon-fiber-reinforced thermoplastic Windform SP. The redesign required only minor shape changes, along with built-in flanges and walls of uniform thickness, to reduce differences in how they flex under high-pressure conditions.

The final intake system consists of three solid pieces—one plenum and two intake manifolds—with the aluminum parts removed and replaced with fully integrated flanges. After heating and shaping the material, the inside channels were smoothed out to make them less rough and help air flow evenly, while CRP Meccanica used CNC machining on important areas to ensure they fit well. The work reflects a coordinated additive–subtractive process inside the CRP group, aligning polymer SLS with post-processing steps typical of metal components.

Engine-dyno tests showed that the structure was strong enough to handle pressure cycles of up to 5 bar, and the assemblies kept their seals and stability. Following bench validation, the intake hardware was installed on the Alpenglow Hy6 prototype for circuit testing, supporting rapid iteration within Alpine’s hydrogen powertrain program.