Mono R Supercar

British manufacturer Briggs Automotive Company (BAC) approaches Malcolm Nicholls Ltd to produce 3D printed parts for new Mono R supercar
BAC came to Malcolm Nicholls Ltd via a recommendation from DSM Malcolm Nicholls Ltd SLA supplier as BAC launched the next generation of the world-renowned Mono single-seater at the Goodwood Festival of Speed in July this year, showcasing a cutting-edge, more organic and lighter design.
BAC co-developed 3D printing applications that were utilised in the manufacturing of the Mono R. This 3D printing offered BAC more freedom to create sinuous, organic designs and achieve significant weight savings.

The Project

To develop the prototype, BAC required many large 3D-printed parts for the Mono R launch and worked with MNL as we have one of the largest 3D printing stereolithography systems available, the RPS NEO800.

Utilising Our Neo800 Large Capacity SLA Machine

Using the NEO800’s 800 x 800 x 600mm platform and DSM’s Watershed resin, MNL successfully produced the large rear wheel arches, each measuring at 915 x 330 x 550mm. The size of the NEO800 platform allowed MNL to produce each wheel arch in one build without the need for cutting parts into smaller pieces. The smooth finish of each part produced on the NEO800 also meant no post-processing, therefore very little or greatly reduced finishing times for paint, resulting in speedy turnaround of parts for MNL.

The Outcome

BAC were so pleased with the work that MNL produced they decided not to use some of the parts they had made previously and use MNL’s parts instead as they felt the service delivery and finish was superior.


BAC Mono Ian Briggs

Ian Briggs, Design Director of BAC, added: “We pride ourselves on being the ultimate pioneers at BAC, and joining forces with DSM, RPS and MNL meant we once again lead the way – this time in terms of additive manufacturing. Keeping the Mono R as light as possible was of paramount importance in its development, and by using 3D printing we not only keep the kilograms down, but also keep sustainability and safety on the up. Using additive manufacturing was crucial for keeping design-to- manufacture times down and allowing us to meet tight deadlines with ample creative freedom – while the quality of the finished result is testament to the work of the NEO800.”

“Without Your Services We Wouldn’t Have Had This Car Ready To Present At Goodwood Festival Of Speed” 

Ian Briggs – Design Director for BAC Mono 


Ross Nicholls

Technical Director at MNL

“The superb smoothness of the parts from this machine is a significant improvement over our previous ones, our high standard of finish can now be achieved more rapidly. Coupled with the extremely large build volume we are able to complete projects in even shorter timeframes.”

NEO800 Large Capacity Machine

Further larger parts were also printed on the NEO800 such as the wide rear wing, spine, wing mirror stays, front light bezels and rear light clusters. Expert finishing from the MNL team completed the final look of some of the parts, such as the polished lens showcasing great optical quality.

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