SPYROS
PANOPOULOS


Automotive Perfection




Project "Chaos"

Redefining the Limits
of Excellence.

"Chaos" to Order.

A Revolutionary
Ultracar.

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History

Spyros Panopoulos Spyros Panopoulos was born on 9th October 1978 in Athens, Greece.

From a very young age he grew to like car technology and speed. His field of study was computer programming and development of applied solutions, both software and hardware.

In 1997 he founded his company based in Greece. Its main activity was programming and mapping of production cars for power increase. In 1998 he acquired his first car dynamometer, which helped to develop his software and hardware applications. Very soon he entered the rally scene, where most of the racing cars in most race types in Greece would be developed by him. His touch reached competitors in the hill climb, speed and dragster races as well as championship motorcycles and offered them performance upgrades as well as victories. He gradually established his name internationally, working with teams of the highest caliber in motorsports, in WRC, BTCC, HILL CLIMB, DRAGSTER, RALLY CROSS, MotoGP and in 2007 he found himself involved with F1, developing high performance motorsport electronics & tuning automotive control systems.

In the meantime, by 2005 he had his own design and production unit of high-spec performance parts of cutting-edge technology for internal combustion engines, applying metallurgy and material mechanics in his research and development. He soon started providing to most racers and enthusiasts in the world his own special parts of the highest specs.

He, too, is a race car driver, holding the world record for acceleration with a 4-cylinder motor car in 4-wheel drive, a Mitsubishi Evo 9 with 7.7 seconds and 308 km/h, for 402 meters. The car is of course developed by him. He also holds the world record for performance of an internal combustion engine per cubic centimeter (cc), in which he races. This is for a motor that he designed and produced himself; the specs are 1788cc, 4 cylinders, 16 valves, with 2880 horsepower in 14100 rpm. That means 1500 hp in the liter.

His firm is now a center for research and development for automotive applications, as well as the military, aerospace and navy. Applications, technologies and innovations that he developed are widely known. In most sports with internal combustion engines, cars, motorcycles or water crafts, and behind every world record you can find a part produced or an idea conceived by him. His designs and technologies for internal combustion engines are widely used by frontline car manufacturers as well as the military. Having developed parts and technologies for most production cars, sports cars and hyper cars, in 2019 he decided to manufacture his own exclusively designed and built car, from scratch. This will change the automotive scene and what driving fast means. Something more than a hyper car.

A new term is needed because a new category is being born. It is called ultra-car. A car far more advanced than anything else out there. Something that will move and impress any car and speed enthusiast. From a simple driver to a race car driver. Faster than anything produced right now, more advanced in all areas, with new technologies and innovative materials. With a power to weight ratio which is close to 2:1, where for every 2 hp there is 1 kilogram of mass. With such a ratio mated to a suitable transmission technology, with the resulting adhesion, the driver will be able to experience accelerations up to 3G, for specific distances and conditions. The vehicle moving from A to B will need half the time needed by a hyper car or mega car. This may require the driver to have special driving skills and a better perception of space in order to reach the vehicle’s potentials. It will be produced in limited production numbers and will materialize in the rarest and most advanced materials that F1, aeronautics and space technology have to offer.

In the section Innovations patents & achievements you will find most of them by date.



Innovations, Patents & Achievements

These are most important prizes as well as his innovations, patents and achievements:


1999

Import aluminum alloy in automotive, for high performance racing use. Design and built his own aluminum rods.

2001

Design and built his own ecu for racing applications, using Motorola processor.

2002

Titanium alloy valves and beryllium valve seats for high temperature turbocharged racing applications for first time in performance automotive.

2005

Design and built the first billet full 5 axis CNC machined compressor wheel for automotive racing turbocharger using just a single raw of blades. 10 and 11 blade design geometry single raw, innovated technology providing higher flow and greater boost pressure ratios on p2/p1 map in lower and higher speeds. Achieving effective boost pressure over 6bar. Leaving back the old 14 blade (7+7) cast wheel design. The compressor wheel blades are in one line fitted to hub and not as the normal old style compressor wheels fitted in two rows (primary and secondary), the benefit of this is that the moving masses of air in the same rotation speed of the compression wheel can improve flow 43%-68% more than any other two row old design, Starting from WRC and lemans turbochargers ending to most of the race classes and categories all over the world.

2006

Develop high flow 10/11 blade turbine wheels one-piece 5axis Inconel 713c and titanium alloy with bigger blades and smaller hub center, offering 33-44% more efficiency than already designs.


Built the first turbo compressor wheel in titanium alloys and magnesium alloys.


Design and milling the first billet steel and titanium camshaft for automotive. Over 6.4 G acceleration ramp with extreme negative ramps.


Milling and design the first full billet engine block and cylinder head from solid T6 aluminum.

2007

Design - develop and manufacture a dual chamber intake manifold system for all levels of motorsport for WRC, kit cars and track day vehicles S2000 spec Rally cars and British touring cars. Offering higher volumetric efficiency and desirable turbulence levels into the combustion chamber.

2008

Design and built titanium flywheels and clutches for high RPM race aplications.


Faster Subaru 4-cylinder engine, faster ford Cosworth, Nissan GTR and more OEM based tuned engines making records on all type of races all over the world.

Built the first +1000hp per 1 litter turbocharged 16v engine. over 2000hp output and 12.800rpm produced from an under stroked OEM 2ltr Mitsubishi evolution engine. Engine specs. 1788cc – 17:1 CR ratio running methanol fuel. 2145hp @ 12400rpm.

2009

Create Unique Pocket design conrod design. After many hours of simulation and finite element analysis (FEA) to analyze the compression and tension forces & stress tests we invent the draft design of "pocket design". This design means that on the two large flat area surfaces on the rod we make small inner round & oval designs that offers ~38% more tension forces than "I" or "H" design, the center area may be machined to create a scalloped effect between the beams, leaving a rounded area next to both beams that increases strength and rigidity much like the filets on a crankshaft journal. Can handle high compressive loads while also providing good tensile strength, and have a thicker cross-section in critical areas to increase strength. But not only the pocket design that makes these rods unique, as using only this design on the rod the rod may bend and fail if the compressive forces are too great. To handle higher horsepower loads on the side beams of the connecting rods that are parallel to the holes in the ends for the piston and pin and crank journal, we built two flat side beams that are perpendicular to the piston pin and crankshaft journal bores. The center area that connects the two sides of the “H” together provides lateral (sideways) stiffness. This type of design can provide higher compressive strength with less weight than a comparable I-Beam. This makes the total design very stiff so it can handle higher compressive loads without bending.


3D billet pistons design, piston Dome is mirror of the cylinder head chamber. A reverse dome is made from scanning the chamber and then made on 5axis cnc machine on to the piston deck. Improving the squish band and engine performance to maximum.


Built and design first tungsten divided H13 tool steel crankshaft for automotive racing application capable of rotating over 14.000rpm. With this design the crankshaft counterweights are removable and can be adjusted on every piston/rod weight and RPM target. Crankshaft counterweights are designed to offset (or balance) the inertia effect of a relatively heavy piston and connecting rod moving in both a rotational and reciprocating (up-and-down) fashion. The weight of the piston and connecting rod combination affects the size and placement of the counterweight. Adjust them can make the vibrations and harmonics run smoothly on very high rpm.


Design and develop high flow cylinder port design and strategies for most OEM car manufactures.

2010

Bring 32CrMoV13 steel from aerospace, to Top fuel, Nascar and IRL making components and crankshafts.

2011

Completely new design from scratch billet engine blocks and high efficiency cylinder heads, direct replacement for OEM engines. Offering higher levels of volumetric efficiency and performance.

2012

"Asymmetrical" design 3D billet pistons 5axis. Every piston has a major and minor thrust side. The major side, due to the direction of rotation and the relative angle of the cylinder sleeve, experiences more side loading than the minor side.

On this design one side of skirt is much smaller, minimized contact patch reduces friction while maintaining stability.

2013

Develop and built parts for aviation, defense & NAVY.


Design and built brake systems from passenger cars to F1.


Design and built 3D skeleton pistons and skeleton titanium rods. The rod and piston are full drilled to save maximum weight. For BTCC and MOTOGP applications.

2015

Making the first full billet 7 axis custom turbo compressor cover from solid aluminum. In centrifugal compressor design, the volute plays a key role in defining the overall efficiency and operating range of the stage. The flow at the impeller outlet is indeed characterized by a high kinetic energy content, which is first converted to potential energy in the diffuser downstream. The compressed gas is then collected by the volute at the cylindrical outlet section of the diffuser and directed to the intake piping, possibly with a further pressure recovery to enhance the stage performance. Due to the high flow speed at the volute inlet, the capability of ensuring the lowest amount of total pressure loss is pivotal to prevent a detriment of the machine efficiency. Moreover, the flow conditions change when the volute operates far from its design point: at mass flow rates lower than the design one, the flow becomes diffusive, while at higher mass flow rates the fluid is accelerated, thus leading to different loss-generation mechanisms. These phenomena are particularly relevant in turbocharger applications, where the compressor needs to cover a wide functioning range, moreover, in these applications, the definition of the volute shape is often driven also by space limitations imposed by the vehicle layout, leading to a variety of volute types. The present paper reports an analysis on the sources of thermodynamic irreversibility occurring inside different volutes applied to a centrifugal compressor for turbocharging applications. With this new design achieves better flow characteristics and lower volute temperatures. Also, can be adjusted on every compressor wheel size and characteristics.


Import Tennalum alloy in motorsport, provides the highest mechanical strength of all aluminum alloys and matching that of certain steels.

This outstanding alloy combines a yield strength of up to 700 MPa (up to over 30% greater than that of 7075 alloy) and good ductility with corrosion resistance similar to 7075 and other features beneficial to high performance component/equipment designers. In strength-to-weight ratio is the best material ever produced, Tennalum® out performs nearly all other engineering alloys in existence (33% better strength-to-weight performance than 7075, and 28% better performance than 6Al-4V Grade 5 Titanium).

For many applications there is no better alloy, not even Titanium. 40% lighter than titanium. Made for aviation, aerospace & defense. He made Rods / pistons /Compressor wheels and more items for motorsports.


"Gen2 patent" 10 blades single raw, design compressor wheel technology, using “super alloy 970mpa” material. 43% lower weight than titanium Ti6AL4v and 35% stronger. A next generation of compressor wheel for a turbocharger revolutionary improved aerodynamically, improved geometry that provides 35-80% more performance as compared with a comparably sized conventional compressor wheel by having the radially inward portion of the primary blades sweep upwardly into the upper region of the hub portion. The through bore and integral nut of compressor wheels is eliminated and replaced with a blade extension that has an angled upper edge which extends downwardly and radially outwardly from the hub portion, that’s the Curve towards the root design, and second base design is the two-way curve in the blade from top view. One way starting from hub with one rotation and at the opposite (end) of the same blade the second curve rotation is different direction. These 2 points (Curve towards the root-hub) and Curve of blade two way effectively increasing the size of the blade, the amount of air movement and the amount of power generated, without increase the size and mases’ weight of the compressor wheel. The compressor wheel blades are in one line fitted to hub and not as the normal old style compressor wheels fitted in two rows (primary and secondary), the benefit of this is that the moving masses of air in the same rotation speed of the compression wheel can be 43%-68% more than any other two row old design.

2016

First full billet high accuracy 7 axis Gen2 “X design” patent piston 3D with patent “3D spiral” oil skirt. Improving lubrication by 58% over the “common” design and lowering friction values on high rpm. Using this technology of spiral grooves improving dramatic higher G acceleration values. X design can secure piston above 38m/sec piston speed.


Carbon fiber Compressor Covers for turbocharger application for first time. Lightweight and lower temperature operation makes them more efficiency expand the compressor wheel map.


Design and built compressor wheels for the most know JET SKI manufactures.


Gen2 compressor wheels from carbon fiber and carbon Kevlar, material composites used for turbocharger applications for first time. 8-10 times lighter than aluminum.

2017

World record in drag racing 4-cylinder Mitsubishi Evo 6/7/8/9 platform. Making the first Evolution 4-wheel drive in 7s. 7.9sec @ 302kmh on 402meters (1/4 mile) & Faster and quicker Mitsubishi Evo 9 on the planet.

2018

New 1/4 mile world record of Evo 7.84sec in Malta 2018 – developing and built the higher volumetric efficiency engine on the planet, producing 1550 hp per 1000cc. 4-cylinder 16v 1788cc with 2880 horsepower at 14,100 rpm, where in addition to a horsepower record maintains the record of higher volumetric efficiency in any internal combustion engine on earth.

2019

New 1/4 mile world record of 7.704sec in Abu Dhabi.


Developing cylinder head designs for many OEM high performance engine for known car manufactures.

EDM pistons for F1, sinker spark erosion technology to motorsport. It’s the first time in piston history that a piston built with this high accuracy technique of sinker spark erosion.


Carbon fiber composite conrods 3D for first time. 10 times lighter than steel alloys.


3D printed pistons from Steel H13 and Titanium Ti6AL4v for racing automotive application.


He invents a new way of creating objects. The material can now take the form and structure it needs only, without unnecessary mass. Depending on the composition, it forms its own form according to the forces exerted on it. He names it "anadiaplasi". The object itself can now be much lighter and much more durable than a solid shape.


3D printed “anadiaplasi” Titanium pistons and rods, next generation of creating objects making masses much lower in weight and more strong than solid.


3D printed "anadiaplasi" Ceramic Rods and pistons. The ultimate material for strength and friction.


3D printed "anadiaplasi" brake systems.


Establishes a new Automotive Company using next level racing technology and expertise to create the most advanced performance Hyper car cars in the world. All the car is made with “anadiaplasi” that makes it extremely light. The monocoque is made from Zylon.


More than 12.000 working hours on dynamometer tuning all kind of ecus, tuned more than 3000 race engine setups.


Project "Chaos"

Sneak Peek

Engine: 3988cc V-10 90degrees – billet Aluminum 5 axis engine block & cylinder heads.
Lubrication – Dry sump.
12.3:1 compression ratio.
20 x fuel injectors (10 x direct injection).
40 x valves.
Titanium Camshafts.
Titanium – Inconel valves.
2000hp - 11.000rpm red line version ("anadiaplasi" titanium 3d printed pistons & rods).
3000hp - 12.000rpm red line version ("anadiaplasi" ceramics 3d printed pistons & carbon fiber rods).
Twin turbocharges – Carbon Fiber gen2 compressor wheels and Carbon fiber compressor Covers, titanium & ceramic compound turbine wheels.
Transmission: 8 speed Dual clutch gearbox, all-wheel drive system.
Chassis: Monocoque Zylon – body parts carbon fiber & Kevlar – titanium & magnesium 3D printed "anadiaplasi" mechanical parts.
Wheels: 22" x 13" rear wheels "anadiaplasi" Titanium 3d Printed & 21" x 9" frond titanium 3d printed.
Brakes: 428mm ceramics discs frond and 416mm rear with "anadiaplasi" magnesium 3d printed calipers.
Suspension geometry: Double wishbone fully independent suspension.
Interior: 2 seats, Augmented reality.


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