How Ford Utilized 3D Printing to Reduce Nurburgring Lap Times by Seconds

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      Recall the scene in Ford v Ferrari where Matt Damon, portraying Carroll Shelby, observes his team removing all the bulky computer equipment from the GT40. When a Ford engineer inquires about their actions, Damon replies, "making your car faster." A somewhat similar but more contemporary event occurred with Ford's latest project: the GTD.

      During the launch of the 2025 Ford Mustang GTD in Palm Springs, Chief Program Engineer Greg Goodall shared with The Drive that the team was 3D printing and engineering components in real-time at the Nürburgring to enhance the car's speed and reduce lap times. The real-time development during testing at the ‘Ring was then relayed back to the team for further refinement and evaluation.

      Goodall noted that in a traditional vehicle development trajectory, there comes a point where engineering and design must be finalized, and ideas are no longer accepted. This moment is often marked by someone saying, “We have to prepare for production, folks.” The GTD, however, deviated from this standard process.

      Joel Feder

      The specific components in question are referred to as “click flicks” positioned around the hood vents. “They resemble little elevated ski slopes,” said Goodall.

      Goodall recounted a call from Mustang GTD Vehicle Dynamics Technical Specialist Steve Thompson, who was at the Nürburgring and mentioned, “Hey, this isn’t part of the design; we 3D-printed some components we’ve been testing here. They could save X amount of time (Goodall did not disclose the exact figure) on the ‘Ring. We want this; can you determine how to implement it?”

      Within a week or two, Goodall’s team and Design Manager Anthony Colard's group devised a design that delivered the downforce Thompson was after. The final design, while drag neutral, also provided the required downforce and additional time on the ‘Ring. Colard stated that the team conducted approximately 20 coefficient drag tests to fine-tune the design, which underwent seven or eight iterations.

      Prior to the installation of the “click flicks,” there was a smoother, lower raised lip, which still exists beneath the new design, with the updated component now affixed to the hood.

      The Mustang GTD team visited the ‘Ring three times before August 2024, when they had the track for their first controlled runs. They returned to the ‘Ring several more times in 2024 and 2025, ultimately achieving the current lap time of 6:52.072 in April 2025.

      The “click flicks” were introduced in May 2024 while Ford was conducting final tests during industry pool days. The initial official attempt to achieve a sub-7-minute lap occurred in August, where the Mustang GTD became the first American car to complete a sub-7-minute lap, clocking in at 6:57.685.

      Goodall remarked that without the “click flicks,” achieving a sub-7-minute lap around the ‘Ring would have been “very tight.”

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