Over the past 5 years, SEAT, the Spanish manufacturer in the Volkswagen Group, has been building CUPRA as a performance sub-brand. The name is derived from CUP and Racing, which reflects the motorsport heritage as SEAT was active in motorsports in the 1990s with an Ibiza model called the Cupra.
As with the performance brands of some other companies, the CUPRA division was born out of SEAT’s unit which was involved in competition and high-performance development. When it started as a business unit, it gained a degree of autonomy in design while using Volkswagen Group hardware. Thus while SEAT products have been largely adapted from Volkswagen models, CUPRA has unique designs that are more sporty and dynamically oriented.
Although CUPRA is today established as the high-performance brand of SEAT, it began as the Special Vehicles department of the Spanish carmaker in 1971. Its main function was to develop and support SEAT’s participation in rallies and touring championships.
In 2018, the name was used as an independent brand with its own line of models focussed on performance and having a more specialised nature, besides individual styling. Its models share technical elements with SEAT models which are also shared within the Volkswagen Group that SEAT is part of.
With its high-performance DNA, CUPRA is naturally a candidate for the virtual world of simulator racing as well. Apart from having its own sim racing series, it is now also on Xbox Game Studios’ and Playground Games’ Forza Horizon 5 with a new all-electric concept racing car.
Like a number of manufacturers, Spanish carmaker SEAT (a member of the Volkswagen Group) also has a performance sub-brand. Known as CUPRA, its name was taken from the high-performance motorsport subsidiary of the company. CUPRA was established in 2018 to focus on high-performance products which, like those of SEAT, uses much of the Volkswagen Group’s technologies and platforms.
The brand has gained a lot of credibility with its high-performance models, delivering close to 200,000 units to date, mostly in Europe. Now it is looking ahead to an electrified future and will launch 3 new electrified models by 2025. The names of the new models were revealed recently – Terramar, Tavascan and UrbanRebel.
“Here is the entire range of CUPRA’s next generation of heroes to be launched by 2025,” said Wayne Griffiths, CEO of CUPRA, at the presentation of the future models. ”In the mid-term, our aim is to deliver 500,000 cars per year and push forward with our international expansion into new markets as well as entering new segments. The CUPRA Tribe is committed to making all this happen, it’s the people that count. Because at the end, it’s the people who make the brand.”
The Terramar
This will be the first electrified SUV of the brand which is expected to move the company to the hotspot of the SUV segment, the fastest-growing segment in Europe. To be produced in Hungary at Audi’s plant, the Terramar will be available with conventional petrol powertrains as well as a new generation of plug-in hybrid powertrains that are promised to deliver around 100 kms in all-electric mode. The e-HYBRID range focuses on performance and contemporary sportiness and are part of the bigger journey as CUPRA fulfils its electrification revolution.
“Terramar, our new sporty hybrid SUV, perfectly combines bold proportions with a long striking bonnet, while the shark nose means breakthrough resistance and the determination to win,” said Jorge Diez, Design Director at CUPRA. “Thinking of how the driver will feel, we provide a unique experience with the latest technology, thanks to the driver oriented interior concept. All in all, a 4.5-metre long SUV, with CUPRA DNA ready to shake one of the most competitive segments”.
Tavascan
In 2024, CUPRA will launch the Tavascan, based on the electrified vision shown in the 2019 concept car of the same name. Some design elements were already strongly hinted at in the 2021 Tavascan Extreme E Concept. The Tavascan will have the mission of globalising the brand and take CUPRA to new markets.
UrbanRebel
In 2025, the UrbanRebel will be the final model to be launched. Its name suggests that it will take the brand beyond its traditional boundaries. It will have an emotional design and be ‘developed for a more rebellious electric world’, according to CUPRA. The front-wheel drive model will sit on Volkswagen Group’s MEB Small platform.
Measuring 4030 mm long, the vehicle has sustainability at its core, integrating advanced recycled polymers and bio-based materials to push the boundaries of what is achievable, and delivering a more environmentally-conscious vehicle. It mixes 3D printed and 3D knitted manufacturing approaches with parametric design to improve performance and value perception.
Lightweight design both in the exterior and interior help the vehicle’s 166 kW (226 ps) electric motor propel the urban electric car to 100 km/h in a claimed 6.9 seconds. The battery pack will have energy to give a range of up to 440 kms.
“The CUPRA UrbanRebel will be the biggest project for our company in the upcoming years since it is key for our transformation as a fully electric brand. We are leading the cluster development, the family of vehicles that will democratise sustainable urban mobility, for different brands within the Volkswagen Group,” said Werner Tietz, Vice-President for Research & Development at CUPRA.
During the impulse event, CUPRA’s CEO also hinted at the future versions of the current range which consists of the Leon, Formentor and Born, to be renewed by 2025.
The Extreme E series, which is the off-road version of Formula E, will enter its second season this year after an exciting inaugural season in 2021. Although 3 of the original venues on the calendar could not be used due to concerns about the COVID-19 pandemic, the organisers still managed to finish the season with 5 rounds in different parts of the world.
This year, there will again be 5 rounds with 7 teams taking part; last year, 9 teams took part. Each team has to have one male and one female, with both taking turns to drive on the competitive stages.
Abt CUPRA Tavascan XE all-electric rallycar in action during the 2021 Extreme E series.
Two Dakar Rally veterans
The Abt CUPRA XE team, which finished 5th overall last year, is among the entrants and its drivers will be Nasser Al-Attiyah and Jutta Kleinschmidt. Both drivers are veterans in off-road events, with Qatari Al-Attiyah having won the Dakar Rally 4 times, his most recent win being this year’s event. German driver Kleinschmidt, who drove for the team in 4 rounds last year, is also a Dakar Rally (2001) winner and is still the only woman to win the world’s toughest rally.
Updated rallycar
The duo will use the new CUPRA Tavascan XE which was shown in concept form about 5 months ago. It is an updated version of the 2021 rallycar and is powered by a 54 kWh battery pack, placed behind the cockpit which contributes to an optimal vehicle weight distribution. It can accelerate from 0 to 100 km/h in around 4 seconds.
The CUPRA Tavascan XE is more sustainable and environmentally-focussed than before. It comes equipped with 3D-printed parts to improve adaptability and make repairing the vehicle far easier and quicker, a crucial consideration when the event venues are in remote areas.
While the bodywork of the all-electric racing vehicle hints at the design language that will be seen on the future series production CUPRA Tavascan, the platform is similar to that used by other teams. Known as ODYSSEY 21, it has a common package of standardised parts and is manufactured by Spark Racing Technology. This encompasses a niobium-reinforced steel alloy tubular frame, as well as crash structure and roll cage, whilst the tyres are designed especially for the extreme conditions by Continental Tyres, a founding partner of the series.
“I’m very excited,” said Al-Attiyah, 51, who has won over 60 rallies and 13 titles. “I believe this is going to be a massive experience for me as the Extreme E Championship is a step forward towards a better future. I’m proud to have joined the CUPRA tribe for this adventure, and I know we can do a great job. The team’s background, combined with the experience of Jutta and me, can consolidate all the great work so far. We are really determined, and the goal is to win. I can’t wait to be sat in the car and start having fun. Let’s make the most of this opportunity!”
First round in Saudi Arabia again
The first round of the 2022 Extreme E series will be on February 19 and 20 in Neom, Saudi Arabia, which should be familiar territory to Al-Attiyah and Kleinschmidt. His closest rival in the desert would be Sebastian Loeb, who has won the World Rally Championship 9 times and is familiar with the Dakar Rally. Loeb’s team mate in the X44 Team, Cristina Gutierrez, has also participated in the Dakar Rally and Extreme E last year. Another veteran off-road driver with experience in Saudi Arabia is Carlos Sainz, who will be in the Acciona | Sainz XE team.
A ship is used to transport the vehicles and equipment to each location, reducing the carbon footprint of the Extreme E series.
At each venue, the participants learn about the environmental issues that need to be addressed and help to create awareness. Researchers also accompany the organisers to conduct studies and collect information, with a Science Laboratory on board the ship for them to use.
The other side of Extreme E
As in the first season, transportation of the vehicles and other equipment to each location is by ship. This is to minimise the carbon footprint Extreme E and though slower, travel by sea is a less carbon-intensive equivalent compared to using aircraft. The ship, called the St. Helena, has been re-engineered to be more efficient and includes a Science Laboratory for use by the researchers who follow the series and conduct environmental studies at each location.
Apart from providing the excitement of motor racing, Extreme E will also be used to raise awareness of environmental and climatic challenges that the world faces, particularly looking at the ecosystems selected for the races. In the case of Saudi Arabia, where the first round will be held, focus will be on the desertification there which epitomises the challenges of the global climate crisis and the importance of regreening and encouraging resilient ecosystems.
CUPRA, the high-performance brand of Spanish carmaker SEAT, was the first carmaker to join the Extreme E all-electric off-road series that started this year, entering in partnership with ABT Sportsline. The 3-year old brand’s involvement is to enhance its R&D while promoting electrification, sustainability, and also gender equality (the series requires each crew to have one male and one female, both to having driving roles).
While the e-SUV used during the current season of Extreme E is one which is common for all teams, CUPRA is already looking ahead when it can develop its own machine. It will become the second manufacturer to use its own bodywork for its team, and Tavascan Extreme E Concept shows what the racing car will look like.
Future design language
It also hints at the design language to be used in the future production CUPRA Tavascan which will be the brand’s second fully electric model designed and developed in Barcelona, Spain and will reach the market in 2024.
“We strongly believe in the Extreme E project as a whole,” said Antonino Labate, Director of Strategy, Business Development and Operations at CUPRA. “Electrification, sustainability, gender-balance and diversity are common values between CUPRA and Extreme E. The CUPRA Tavascan Extreme E Concept is clear proof of the hard work that we’re doing at CUPRA in order to be able to compete next season.”
Completely redesigned exterior
The Tavascan Extreme E Concept integrates a completely new exterior design with 100% CUPRA DNA and a holistic approach to natural material use making it more sustainable, adaptable and easy to repair. The front and rear design has changed considerably from the vehicle that is racing in the first season of Extreme E.
LED technology delivers greater freedom to produce a vehicle with CUPRA DNA, with the headlights in groups of three triangles on either side providing a more imposing look. The LED lighting is set into a 3D-printed frame – a technology chosen to gain a competitive edge. The 3D-printed parts can be manufactured in just 6 hours, meaning the team can adapt to changes very quickly. Whether it’s because of an incident or changes to the light position, the components can be modified in a very short time without the need for cumbersome and expensive tooling.
3D-printed elements for bodywork
“The CUPRA Tavascan Extreme E Concept is the next evolution of our all-electric off-road racing car with even more CUPRA DNA and a design that hints at the brand’s future direction. But it also delivers technical advancement too,” said Head of Technical Development at CUPRA Racing, Xavi Serra. “The concept car uses flax fibres throughout the bodywork to improve sustainability and 3D-printed elements that can be quickly recreated to keep the race car out on the track.”
Constructing as much of the body structure as possible from flax fibres – extracted from the flax plant – reduces the use of carbonfibre components and the vehicle’s impact on the environment. The material can be worked in the same way, achieving the same shapes and radii required by engineers, and is a technology that could easily be adapted for production vehicles.
The e-SUV concept is finished with copper accents – a time-honoured CUPRA mark – parametric texturing and dynamized lines to help the exterior shimmer and move as the vehicle shifts through the landscape, and an overlapping CUPRA logo to create a powerful 3D effect.
“I am delighted to see CUPRA launch the Tavascan Extreme E concept as it enables it to become the second manufacturer to use its own bodywork for its Extreme E team. This move not only injects added style and personality into the series, but also supports our goals for Extreme E to prove itself as a global marketing showcase for partners, as CUPRA prepares to launch this model to consumers in the future,” said Alejandro Agag, Founder and CEO of Extreme E.
The e-SUV used by the ABT CUPRA XE team in the first and current season of Extreme E .
CUPRA, the high-performance subsidiary of Spanish carmaker SEAT, has revealed the design language that will be used for its urban electric vehicle (EV). Instead of just sketches, the company has built a full-sized prototype which it calls the CUPRA UrbanRebel Concept that will be displayed at the IAA Munich International Motor Show this month.
The CUPRA UrbanRebel Concept is designed as a racing car to push the limits in a radical interpretation of an urban electric car. Having a racing car as the basis for the design is because Racing is at the core of CUPRA’s DNA.
New electric car to be launched in 2025
“The CUPRA UrbanRebel Concept is a radical interpretation of the company’s urban electric car, due to be launched in 2025. This racing concept gives an idea of the design language of the future street-car and will inspire its creation” said Wayne Griffiths, CEO of CUPRA. “It builds on the design foundations of the 100% electric urban vehicle, that will be launched in 2025.”
This racing version will influence the road version of the urban electric car, but the core elements are enhanced to give the vehicle an even more rebellious character. At the front, the shark nose was created using a negative surface. The front face is also emphasized by the new triangular signature in the headlamps.
Its wraparound window graphic generates the visual effect of a helmet – as in the CUPRA Tavascan Concept – and gives continuity between the windows around the whole car to deliver the effect of a floating roof.
Moving to the side, the car shows athletic proportions, thanks to the wedge line – from the C-pillar to the front door – with diagonal sculptural surfaces., that create tensional contrast. The rear view of shows athletic shoulders, in a new interpretation of the design seen in the CUPRA Formentor.
Influence from virtual world
The rear features an iconic design, thanks to horizontal proportions. On top of that, the large spoiler – usually seen on racing cars seen in the virtual world – gives it an imposing sharp look underlined by the negative surface beneath it.
“The CUPRA UrbanRebel Concept injects a gamification look to the racing car, projecting a radical interpretation of the company’s urban electric car,” said Jorge Diez, CUPRA Design Director. “Each contoured line and sculpted surface in the design is brought to life by a livery that uses kinetic particles to add movement to the surface as light shifts across it.”
Volkwagen MEB platform for EVs
The car’s overall length is 4080 mm, with a width of 1795 mm and height of 1444 mm, which makes is slightly larger than a Volkswagen Polo but smaller than a Golf. It sits on the Volkswagen Group’s MEB (modular electric drive matrix) platform engineered for EVs. The output for the concept car is said to be 250 kW of continuous power and up to 320 kW at its peak. The factory claim for the 0 to 100 km/h sprint is 3.2 seconds.
Volkswagen Group MEB platform designed for electric vehicles.
The CUPRA UrbanRebel Concept is more than just a preview of a new model for CUPRA. It also involves the rest of the Volkswagen Group, which SEAT is part of. “The urban electric car is a key strategic project not only for our company, but also for the Volkswagen Group, as our aim is to produce more than 500,000 urban electric cars per year in the Martorell factory in Spain for different Group brands. The urban electric car will democratise and make accessible electromobility to the masses,” said Griffiths.
Extreme E is a new off-road series which, like Formula E, will be for all-electric vehicles. Set to start off in January 2021, the series will have 5 rounds in places which have been damaged or affected by climate change. The environments will be Arctic, Desert, Rainforest, Glacier and even Ocean.
While some companies have expressed interest in participating, CUPRA, the high-performance brand of Spanish carmaker SEAT, has confirmed its commitment to the event. CUPRA will collaborate with ABT Sportsline as the racing team’s main partner, and will contribute a team of engineers and drivers.
Electrification and sportiness
“CUPRA and the Extreme E competition hold an identical challenger attitude to prove that electrification and sportiness can be a perfect match. Such partnerships boost our path towards electrification as we will have 2 plug-in hybrid models by the beginning of 2021 and our first all-electric vehicle, the CUPRA el-Born, that will be ready by the second half of next year,.” said President of SEAT & CUPRA, Wayne Griffiths.
CUPRA’s enthusiasm should be a surprise as the brand has already been involved in electrically-powered racing cars. It developed the CUPRA e-Racer which is the world’s first all-electric racing touring car, powered by 4 electric motors that deliver a combined 680 ps/ 960 Nm.
That project helped the brand develop its knowledge base as it continues along the road towards electrification of its passenger vehicle line-up. Now it has the CUPRA Leon plug-in hybrid, which will be followed at the beginning of 2021 by the CUPRA Formentor plug-in hybrid, and then the CUPRA el-Born in the second half of next year.
Crews must have one male, one female
The Extreme E has a gender equal sporting format whereby teams must field one male and one female driver. The first of these is CUPRA e-ambassador, Rally Cross and DTM Champion, Mattias Ekstrom.
Sara Price is one of the drivers in the event, and she will be with the American Chip Ganassi Team.
“Extreme E is a mix of Raid and Rally Cross, racing through very different environments with tracks marked using GPS,” said Ekstrom. “But it holds a lot of promise for developing electric vehicles; collecting data to feedback into cars in areas such as software and regeneration.”
There are a great many areas where know-how can be transferred, that should bring huge developments to future vehicles in areas including driveability, power delivery, chassis setup and steering. Additionally, participating in Extreme E will boost the visibility of the brand.
Where and when
The championship, managed by the same organisation that does Formula E, is recognised as an FIA International Series. At the time of writing, there are 8 teams on the list of participants, with CUPRA being the first carmaker to join.
Extreme E’s will see the participants and their vehicles and equipment going around the world. To provide transport to remote locations, a floating paddock and base has been developed. This is the RMS St. Helena, which will be used to transport the championship’s freight and infrastructure, including vehicles, to the nearest port to each of the 5 locations. This will also minimise Extreme E’s emissions profile as well as facilitating scientific research through an on-board laboratory.
SEAT, like other carmakers (especially in Europe), is steadily making the transition towards electrification, an important move to meet increasingly tough legislative requirements in the years to come. The emission levels are so low that it is necessary to use hybrid powertrains if not all-electric ones to meet them.
Interestingly, however, the Spanish carmaker will launch its first all-electric model next year using its high-performance CUPRA brand rather than the SEAT brand. The reason for this is said ‘to be to change the dynamic perception of electrically-powered vehicles’.
The new electric model will be based on the el-Born Concept which was shown at the Geneva Motor Show in 2019. Since then, the design team and the SEAT Technical Centre have been working on the production model, continuing to evolve the vehicle. Some of the changes they have made have given it a sportier character and an even more impressive visual appeal.
“CUPRA el-Born displays all the genes of the CUPRA brand and we have taken the original concept to the next level creating a new sporty and dynamic design and reengineering the technological content. CUPRA el-Born is the living proof that performance and electrification are a great match,” said CUPRA CEO Wayne Griffiths.
The SEAT el-BORN concept which was displayed in Geneva last year.
The performance and dynamics of the CUPRA el-Born have been a clear focus during the development of the car, and acceleration from 0 – 50 km/h will be within 2.9 seconds. The Dynamic Chassis Control Sport (DCC Sport), which has been exclusively developed within the VW Group MEB platform for the CUPRA el-Born, combines the low driving height of the car with a system that is adapting automatically to any conditions, offering a superior level of driving dynamics.
For now, the company will reveal that the el-Born will have features such as Head-up Display with Augmented Reality and a range of up to 500 kms on a fully charged battery pack. The 77 kWh battery pack can be fast-charged within 30 minutes which will provide at least 260 kms of range, it is claimed.
The interior is designed to encapsulate the CUPRA philosophy of quality and performance mixed with sophistication. This is highlighted in the sports bucket seats, the steering wheel with Drive Profile Selection and CUPRA mode buttons, and high-quality material choices. CUPRA puts a particular focus on the sustainability of the el-Born using recycled materials in the interior of the car.
The Volkswagen Group factory in Zwickau, Germany, will produce electric vehicles for the various brands, including SEAT and CUPRA.
The model will be manufactured at the Volkswagen Group factory (SEAT is part of the Group) in Zwickau, Germany. This factory has been renovated and configured to produce electric vehicles for the Group’s different brands from 2021. It will have a production capacity of up to 330,000 electric vehicles a year.
Nobody can see it, but it is a factor in a car’s fuel consumption, safety and comfort. It’s called aerodynamics, or the study of how air moves around solid objects. In the automotive world, its application is very practical: reducing a car’s resistance to wind. And all this is tested in its ‘temple’, the wind tunnel. This is how it works.
A hurricane in the room
Typically, prototypes are placed in the middle of a chamber, securely kept to the floor. Huge fans generate airflow and the vehicles can face winds of up to 300 km/h while sensors study their individual surfaces.
The air travels in a circular motion, depending on the size of the rotor and blades. Needless to say, when it’s blowing at full power, no one will be allowed inside the chamber as they would literally get blown out of it.
The car’s resistance data is displayed on the computer screens. Hundreds of numbers to be interpreted and compared to even the smallest variable to improve aerodynamics. Every millimetre of each part is key, since it is not only possible to reduce consumption, but also to increase stability, comfort and safety.
Shaping to go faster
Wind tunnels, while primarily used for development of future models, are also valuable for racing cars. While the goal in aerodynamic efficiency for production models is to lower fuel consumption and improve stability, when it comes to racing cars, optimising the bodywork to achieve higher speeds is the aim.
The performance of rear wings, for example, can be optimised for the best downforce.
CUPRA Racing’s Head of Technical Development, Xavi Serra, explains: “We want the new CUPRA Leon Competicion to have less air resistance and more grip when cornering. First, they will have to compete against the wind. Here we measure the parts on a 1:1 scale with the real aerodynamic loads and we can simulate the real contact with the road. This gives us the result of how the car will perform on the track.”
235 km/h standing still
The facilities where the CUPRA engineers test their prototypes are among the most complete and innovative. They have a special feature that makes the tests seem as if they are made in near-real conditions. However, instead of the car travelling at up to 235 km/h, the same effects are achieved by making the air travel at those speeds.
“The most important thing is that we can simulate the road. The wheels turn thanks to electric motors that move belts under the car,” said Wind Tunnel engineer Stefan Auri.
After hundreds of measurements, the results are compared with the car’s previous generation. “In this sense we’re satisfied; we’ve lowered the drag and improved the downforce, so it’s more efficient than the previous model, which will give us better lap times on the track,” said Xavi, adding that the data obtained will also be used to improve the new CUPRA models.
Supercomputer crunches numbers
The wind tunnel is not the only tool for improving aerodynamics. Supercomputing also plays a key role. When a model is in the early stages of development and there is not yet a prototype to study in a wind tunnel, 40,000 laptops working in unison are put to the service of aerodynamics. This is the MareNostrum 4 supercomputer, the most powerful in Spain and the seventh in Europe. Scientists around the world use it to carry out all kinds of simulations, and in the case of a collaboration project with SEAT, its computing power is used to battle the wind.
At first glance, it looks like a normal mirror, but it isn’t. It is a 3D-printed part, a technology that CUPRA has begun to implement in the development of the new Leon Competition racing car in collaboration with HP. Greater agility, efficiency and flexibility are the benefits of a system that is set to revolutionise car development.
“For the new CUPRA Leon Competition, we modelled the steering wheel’s centre control module, the bonnet air vents, door mirrors and the brake and water-cooling inlets,” explained Xavi Serra, the Head of technical development at CUPRA Racing. “These parts were produced using HP’s industrial-grade Jet Fusion 5200 3D printing solution and included in the demanding development tests put to the new racing model.”
More efficiency, greater speed
The main goal with this technology, which offers multiple benefits, is to have a lot of parts in a short time. Engineers can quickly test a wide variety of designs and furthermore, since vehicle development is now done in parallel, this technology enables quicker response to any changes in the design process.
“The work with CUPRA demonstrates the power of 3D printing and digital manufacturing – changing the way the world designs and manufactures,” said Virginia Palacios, Head of Systems Product Management, 3D Printing & Digital Manufacturing, HP Inc.
Wind-tested 3D parts
In TCR competition, the door mirror is a part which, according to the rules, must have the same shape as the production car. But the CUPRA engineers went one step further. “We wanted to add an additional function, which is to cool the driver. We therefore had to design an air intake in the maximum pressure zone to achieve this effect,” said Xavi.
The place where these materials are tested is the wind tunnel, where the 3D-printed parts are verified in exactly the same way as the rest. “The bigger the variety of parts we can test in this facility, the better. It enables us to make much faster progress,” he added.
The new Leon Competition with its 3D printed parts was tested to the limit on the Portimao track in Portugal.
As it is a racing car, the final phase of development can only be carried out in one place: the circuit. “The results were excellent, and some were even surprising, because we were looking to push the material to its limits,” the CUPRA engineer reported.
Making complex ideas a reality – fast
“3D printing is going to signal a turning point in the automotive industry by accelerating lead times and HP 3D technology is helping designers create parts that could not be produced with other technologies,” said Palacios, predicting that the technology will continue to be key in countless fields to make the most complex ideas a reality.
