The Bacalar spearheads a return to coachbuilding by Bentley Mulliner and features an enhanced version of Bentley’s peerless 6.0-litre W12 TSI engine, the most advanced 12-cylinder engine in the world.

Since the first introduction of the twin-turbocharger W12 in 2003, the engine’s refinement has seen an increase of up to 27 percent in power, 38 percent in torque and a reduction of 38 percent in emissions.

This has been realised through the evolution and optimisation of the crankcase, improvements in the oil and cooling systems, twin-scroll turbocharging technology and more effective injection and combustion processes.

Sources from Bentley told this correspondent that these improvements resulted from several initiatives taken by the company. It may be recalled that the latest generation of W12 was launched in the Bentayga in 2016. “A thoroughly reworked engine included a crankcase 30 percent stronger than its predecessor, while the cylinder surfaces were coated to reduce friction and improve corrosion resistance. A low-alloy steel coating is applied to the bores using an Atmospheric Plasma Spray (APS) process. Improvements were also made to the cooling system, with the engine featuring three separate coolant circuits. The first is designed to bring the cylinder heads up to optimum operating temperature as quickly as possible for best engine performance and low emissions. The second cool the engine block and oil system, while the third handles the turbochargers’ thermal load. Each system has a dedicated water pump, allowing optimised individual control,” sources said.

Twin-scroll Turbocharging

Twin-scroll turbochargers minimise turbo response time and provide a more efficient exhaust package. The exhaust assemblies for the three front and three rear cylinders are separate from one another, which feed the twin-scroll impellers. The turbocharger housing is welded directly to the exhaust manifolds and feature integrated speed sensors, allowing the engine to monitor turbo performance for maximum efficiency.

Effective Injection

The W12 combines high-pressure direct fuel injection (200 bar injection pressure) with low-pressure port injection (six bar). The combination of these two systems maximises refinement, lowers particulate emissions and optimises power and torque delivery.

Interestingly, each W12 engine is hand-built over 6.5 hours by a team of 45 craftspeople before undertaking a highly sophisticated test regime of over an hour via three specialist diagnostic machines during the engines assemble.

According to the sources, there were three specialist diagnostic machines with sophisticated test regime.

Leak Test

The leakage test is conducted by pressurising each of the systems for fuel, oil and water individually. The different cavities are pressurised to values between 0.2 – 5.0 bar respectively and then measured whilst the pressure decays over time. The reduction in pressure versus time represents the quality of the sealing of the engine assembly. If the pressure drops faster than expected, a leak is indicated. A special fluid is sprayed on to the exterior of the engine to pin-point any leakage paths.

Cold Test

The engine is loaded on to a testbed plate, and connections are made to the engine loom and all engine systems, whilst a large electric motor couples to the engine via the crankshaft. “Motoring” the engine via the crankshaft allows the testbed to collect data from a suite of sensors. The facility measures 600 individual properties and characteristics of the engine during a 15-minute cycle. Due to the low running speed of 120 RPM for the test, finer details and any inconsistencies can be identified thanks to a sample rate that highlights even the briefest of anomalies that would be invisible if the engine was firing or running at speed. This fine detail analysis is also valuable for confirming the precise timing of the engine. Using positioning information from sensors on the crankshaft, crankcase and camshafts, and cylinder compression values, the Cold Test can confirm the engine timing is accurate and, therefore, achieve the best possible combustion cycle.

Hot Test

When the engine arrives for hot testing, a UV dye is added to the engine to help identify any leaks. The coolant and fuel system are pressurised with air and nitrogen, respectively, for a final check before introducing the necessary fluids ready for testing. The engine is cranked to build oil pressure before the ignition system is energised and then left to idle whilst the engine test technician listens for any refinement issues and checks for leaks with a UV lamp. Sources said that each W12 is then tested for a minimum of 21.5 minutes and runs up to 3,800 rpm with a maximum load of 300 Nm. One in every one hundred engines receives a full eight-hour power test, achieving 6,000 RPM, and must achieve 900Nm.

The three tests that the Bacalar engine has already been put through are part of Bentley’s exceptional quality control processes. These testing procedures provide feedback on the quality of each engine and provide multiple checkpoints to catalogue the exact behaviour of each engine from the moment of manufacture. Since the installation of the three testbeds in 2002, over 100,000 W12 engines have been handcrafted in Crewe and passed through the test facility.

Technology Advancements

Bentley’s legendary 6.0-litre twin-turbocharged W12, created in 2002, has evolved into the latest iteration of the W12 engine used across today’s current model range. The unique W-configuration means that the engine is 24 percent shorter than an equivalent V12, benefitting packaging and maximising usable cabin space.

The latest generation of W12 was launched in the Bentayga in 2016. A thoroughly reworked engine included a crankcase 30 percent stronger than its predecessor, while the cylinder surfaces were coated to reduce friction and improve corrosion resistance. A low-alloy steel coating is applied to the bores using an Atmospheric Plasma Spray (APS) process.

The W12 combines high-pressure direct fuel injection (200 bar injection pressure) with low-pressure port injection (six bar). The combination of these two systems maximises refinement, lowers particulate emissions and optimises power and torque delivery.

Twin-scroll turbochargers minimise turbo response time and provide a more efficient exhaust package. The exhaust assemblies for the three front and three rear cylinders are separate from one another, which then feed the twin-scroll impellers. The turbocharger housing is welded directly to the exhaust manifolds and feature integrated speed sensors, allowing the engine to monitor turbo performance for maximum efficiency.

Bentley’s variable displacement system shuts down half of the engine under defined conditions. Intake and exhaust valves, fuel injection and ignition are all shut down on defined cylinders, with the engine running as a six-cylinder for improved efficiency. The system will run in this mode in gears three to eight, below 3,000 rpm and up to 300 Nm torque output.

The first Bacalar engine followed the same build process in Bentley’s centre of excellence for W12 engines, ensuring the same level of quality and expertise before final testing, sources added. (MT)

Sustainable, Recyclable Electric Motors

Bentley Motors has announced a three-year research study that aims to revolutionise the sustainability of electric motors. Supporting Bentley’s commitment to offering only hybrid or electric vehicles by 2026, the result could see recycled rare-earth magnets used in selected ancillary motors for the very first time.

The study, titled RaRE (Rare-earth Recycling for E-machines), intends to build on work completed at the University of Birmingham in devising a method of extracting magnets from waste electronics. The project will also scale up this process and repurpose the extracted magnetic material into new recyclable magnets for use within bespoke ancillary motors.

Adding to the sustainability benefits that RaRE will provide, the bespoke motors created through this method promise to minimise complexity through manufacture while supporting the development of the UK supply chain for both mass production and low volume components.

Dr Matthias Rabe, Member of the Board for Engineering, Bentley Motors, said, “As we accelerate our journey to electrification, offering only hybrid or electric vehicles by 2026, and full electric by 2030, it is important that we focus on every aspect of vehicle sustainability, including sustainable methods of sourcing materials and components. RaRE promises a step-change in electrical recyclability, providing a source of truly bespoke, low voltage motors for a number of different applications, and we are confident the results will provide a basis for fully sustainable electric drives.”

This study will run in parallel to Bentley’s OCTOPUS research programme, which aims to deliver a breakthrough in e-axle electric powertrains, utilising a fully integrated, free from rare-earth magnet e-axle that supports electric vehicle architectures.

As with OCTOPUS, RaRE is an OZEV funded project delivered in partnership with Innovate UK, which brings together the following partners with distinct roles and responsibilities. Bentley Motors will lead specification setting and test protocol development and support the design and manufacturing activities, while Hypromag will scale up the recycling processes developed at the University of Birmingham and convert the extracted powders to sintered magnets with properties designed around those required for the auxiliary motors. On its part, Unipart Powertrain Applications Ltd will lead the development of manufacturing scale-up routes to ensure facilities and processes defined are suitable for volume automotive manufacture.

Advanced Electric Machines Research Ltd will lead the motors’ design and development, while Intelligent Lifecycle Solutions Ltd will pre-process computer hard disk drives to remove the rare earth magnet containing components from the waste, which will be shipped to Hypromag for removal of the rare earth magnets. The University of Birmingham will provide cast alloys, which will be fed into Hypromag to blend with secondary materials to produce sintered magnets. (MT)

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Automotive major Stellantis has announced the formation of the Europe Supplier Advisory Council, a forum intended to increase collaboration between the carmaker and its supply chain. The council brings together senior Stellantis leadership and 26 supplier partners representing various automotive technologies and commodities.

The council will convene for three sessions during 2026, with each meeting lasting 1.5 days. The initiative includes participation from major European supplier associations, ANFIA and FIEV, to provide a collective voice for the regional supply base.

The Council's primary functions include:

• Operational Efficiency: Identifying bottlenecks and improvement opportunities across the value chain.
• Strategic Workstreams: Establishing joint Stellantis-supplier groups focused on production planning, cost competitiveness and operational excellence.
• Innovation Readiness: Accelerating the deployment of new technologies and ensuring launch readiness for future vehicle programmes.
• Regulatory Alignment: Addressing European Union regulatory requirements and geopolitical instability.

The council is designed to modernise supplier partnerships amid technological shifts and market volatility. By co-leading workstreams, Stellantis and its partners aim to align performance expectations and enhance the resilience of the European manufacturing and R&D platforms.

Emanuele Cappellano, COO, Stellantis Europe, said, “The launch of the Europe Supplier Advisory Council represents an important milestone in our journey to strengthen the region’s industrial performance. Today, more than ever, our success depends on deep collaboration with our supplier partners. By creating a shared forum where we openly discuss challenges and opportunities, we are building the foundation for faster execution, stronger competitiveness, and sustainable growth across Europe.”

Stephane Dubs, SVP of Purchasing and Supplier Quality for Stellantis Europe, added, “Our suppliers are essential contributors to Stellantis’ transformation. This new Council allows us to work side-by-side, with transparency and respect, to co-create solutions that benefit both sides. Together, we will address the critical issues shaping our industry—whether in quality, launch readiness, cost competitiveness, innovation, or supply chain resilience—and turn them into strategic advantages for our entire ecosystem.”

Jean-Louis Pech, President, FIEV, commented, “FIEV welcomes the opportunity to join Stellantis Supplier Advisory Council, which represents a valuable opportunity to strengthen our relationship and enrich the dialogue with suppliers. This participation will enable us to represent, with ANFIA, the collective voice of suppliers and actively contribute to the Council’s work.”

Marco Stella, President, ANFIA Components Group and Vice-President of ANFIA, stated, “Now more than ever, it is essential to invest in a fruitful partnership between Stellantis and the supply chain ecosystem, caught between European market weakness, geopolitical instability and fierceful competition, also to face united and together EU regulatory challenges and support EU manufacturing and R&D platforms.”

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Spinny, an Indian full-stack used car platform, has announced that it recorded a threefold increase in vehicle deliveries on Gudi Padwa compared to standard operating days. The surge indicates a trend of consumers aligning automotive purchases with festive milestones.

The festive period saw a 50 percent increase in footfall across Spinny Car Hubs in the days leading up to the holiday. Its data suggests that 86 percent of customers experienced a standard delivery process despite the heightened activity.

Regional demand was concentrated in western and southern India:

• Maharashtra: Pune and Mumbai recorded over six times their average daily delivery volumes, with each city serving more than 100 customers in a single day.
• Geographic Contribution: Maharashtra, Andhra Pradesh, Telangana and Karnataka collectively accounted for 70 percent of total deliveries on the day.

In terms of demand trends, Hyundai Motor India and Maruti Suzuki India were the most preferred auto brands, while Hyundai Grand i10 was the most purchased vehicle. White remained the most popular exterior colour across all markets. It saw 53 percent of buyers utilised credit solutions to fund their purchases, reflecting a shift towards structured ownership.

Hanish Yadav, Senior Vice-President, Spinny, said, “Gudi Padwa holds deep cultural significance as a time of renewal and new beginnings. We are witnessing more customers align their car-buying journeys with such meaningful occasions. The strong surge in deliveries and increased engagement across our hubs reflects both evolving consumer intent and the trust placed in Spinny. Our focus remains on ensuring a transparent, reliable, and high-quality experience - regardless of demand cycles.”

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Renault India has officially released the ARAI-certified fuel efficiency figures for the newly launched Duster, which is now powered by the Turbo TCe 160 engine. This latest iteration of the SUV delivers a fuel economy rating of 18.45 kmpl when paired with the DCT automatic gearbox, while the version equipped with the six-speed manual transmission achieves a rating of 17.75 kmpl.

Developed specifically to suit Indian driving conditions, the vehicle combines robust performance with what Renault describes as best-in-class ride and handling characteristics. At the heart of the Duster is a turbo-petrol unit that generates 163 PS of power along with 280 Nm of torque, securing its position as the most powerful engine in its category.

Through intelligent engineering and a carefully optimised powertrain, Renault has managed to create a compelling balance that merges high output with segment-leading fuel efficiency, ensuring drivers do not have to compromise between spirited performance and economical running.

Dr V Vikraman, Chief of Renault Engineering, Renault Group India, said, “The ARAI-certified figures highlight the strength of our technology and our commitment to delivering superior all-round value. New Renault Duster’s Turbo 160 engine integrates advanced solutions such as low-friction coatings and high-pressure fuel injection to optimise combustion and efficiency. Paired with Renault’s latest DCT automatic transmission, which ensures fast and seamless gear shifts, the powertrain delivers an excellent balance of performance and fuel efficiency while remaining strong and responsive on the road.”

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South Korean automotive major Hyundai Motor Company has named Bradley J. Arnold as Chief Designer and Head of Hyundai Design North America (HDNA) in Irvine, California.

He will oversee vehicle and concept design for the North American market, focusing on the company’s design-led strategy.

Arnold rejoined Hyundai in 2016 and has held various leadership roles within the California studio. Since 2021, he led the exterior design team, contributing to the 2023 Hyundai Palisade facelift and the 2022 Hyundai Santa Cruz. His previous experience includes:

• Hyundai (2008–2011): Contributions to the Hyundai Genesis Coupe exterior and Hyundai Curb Concept interior.
• General Motors Design (2011–2016): Work on the Cadillac Elmiraj Concept, Chevrolet Tru 140S, and mobility concepts.
• Academic: Graduate of and former instructor at the ArtCenter College of Design.

In 2025, Arnold served as interim design head at HDNA, where he managed the development of production and concept vehicles. He directed the global XRT off-road strategy within 'The Sandbox,' a design hub at the California studio.

Under his guidance, this facility has produced the 2026 Palisade XRT PRO, the CRATER Concept, and upcoming XRT models scheduled for production.

Luc Donckerwolke, Executive Vice-President and Chief Creative Officer, Hyundai Motor Group, said, “Design is the clearest expression of our ambition as a brand. Brad brings clarity, courage, and a strong connection to North American customers. His leadership will be instrumental as Hyundai Design North America shapes vehicles that are both emotionally engaging and globally relevant.”

SangYup Lee, Executive Vice-President and Head of Hyundai and Genesis Global Design, commented, “With more than 18 years of experience working with highly respected global automotive brands, Brad brings an exceptional level of creative leadership and vision. We are excited to have him lead Hyundai Design North America and build on the strong momentum of our vehicle design direction.”

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