Spanish performance brand CUPRA Racing has leveraged PTC’s cutting-edge CAD and PLM solutions for over 20 years to revolutionize its design process. What began with basic 2D component modeling in 1998 has evolved into full 3D vehicle visualization, with engineers now able to digitally assemble complete racecars before manufacturing. This technological partnership is proving instrumental as CUPRA transitions to electric motorsports in Extreme E and FIA ETCR championships.
From Digital Skeletons to Race-Ready Assemblies
At the heart of CUPRA’s design revolution is PTC’s Creo software, which enables a top-down engineering approach. Designers first create a digital skeleton model that defines the vehicle’s core structure. When modifications occur, changes automatically propagate across all connected components. “We’ve eliminated the costly errors of our 2D past,” said Jaume Tarroja, CUPRA’s Head of Full Vehicle Design. The system’s finite element simulation capabilities further allow engineers to stress-test components in virtual environments before physical production.
Wiring the Future of Electric Motorsport
PTC’s solutions now extend beyond mechanical components to electrical systems. Engineers can digitally simulate complete wiring harnesses and fluid piping systems, ensuring flawless first-time installation. This capability proves particularly valuable for CUPRA’s electric racecars, where complex high-voltage systems demand precision engineering. The digital-first approach has yielded tangible results: lighter components, reduced development costs, and measurable performance gains across 70 races in 2022 alone.
Continuous Improvement in the Digital Age
“In motorsport, standing still means falling behind,” Tarroja emphasized. The PTC platform enables CUPRA to iteratively improve designs while controlling costs—a critical advantage in budget-conscious racing categories. Windchill PLM serves as the central nervous system, managing all technical data and enabling seamless collaboration across CUPRA’s engineering teams. This digital backbone ensures knowledge retention even as regulations and technologies evolve.
From Track to Road: Electrification Lessons
CUPRA’s racing innovations are directly informing its road car electrification strategy. The same digital tools optimizing Extreme E battery packaging are being adapted for consumer EVs. By perfecting electric powertrains in the crucible of competition, CUPRA is accelerating its transition to sustainable performance—proving that in modern motorsport, software is becoming as crucial as horsepower.
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