When we recently covered Joel Artursson’s groundbreaking 3D-printed Saab B2x4/B2x5 exhaust manifold, the story centered around a single prototype and the engineering problem that inspired it. Now, the Swedish Saab tuner has revealed something equally interesting: the project is already evolving beyond the prototype stage.
According to Joel, the second 3D-printed manifold was designed and printed earlier this year, during January and February, and was intended for fellow Saab enthusiast Joakim Karlsson and his Saab project powered by a Garrett G25-660 turbocharger. More importantly, Joel says this latest version represents a significantly more mature design than the original unit fitted to his own car.
“The latest design is no longer a prototype,” he explains. “Now the design is really optimized for manufacturing.”
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A Better Print Than the Original
The first manifold attracted attention because it demonstrated that complex Saab exhaust geometry could successfully be produced using industrial metal additive manufacturing. Printed in 316L stainless steel using SLM/DMLS technology, it offered shapes and internal transitions that would be extremely difficult to reproduce through conventional fabrication.
The second manifold builds upon everything learned from that first project.
Joel reports that the printing quality is even better than on the original prototype, reflecting both improvements in the design itself and a growing understanding of how to optimize parts specifically for industrial metal printing processes.
The visual differences may appear subtle, but for a component designed to handle extreme exhaust temperatures and support large turbochargers, manufacturing optimization matters just as much as flow characteristics.
Six Saab-Specific Designs Already Exist
Perhaps the biggest revelation from Joel’s latest update is that the project has expanded far beyond a single manifold design.
By early 2026, Joel had completed six different versions, all developed around a principle that Saab owners will immediately appreciate: retaining compatibility with the factory heat shield.
That decision remains one of the most Saab-like aspects of the entire project. Despite being designed for power levels far beyond anything envisioned in Trollhättan, the manifolds still preserve the discreet appearance and thermal management benefits of the original setup.
Supporting Everything From TD04HL to Modern G-Series Turbos
The six designs cover a surprisingly broad range of turbocharger combinations.
For enthusiasts running traditional Saab-based setups, Joel has developed versions intended for the original TD04HL turbo position, including configurations using T25-style turbine inlets for both standard and heavily ported turbine housings. He notes that popular upgrades such as the King Cobra intake pipe remain fully compatible.
The project then expands into more serious territory.
Additional versions move the turbocharger position to accommodate a wide variety of modern performance turbos, including:
- Garrett GTX2867R
- Garrett GTX3076R
- Garrett G25-550
- Garrett G25-660
- Garrett G30-770
- BorgWarner EFR 6258
- BorgWarner EFR 7163
Both Generation 1 and Generation 2 Garrett units are supported where applicable.
More Than a One-Off Experiment
What makes this update significant is that it changes the nature of the original story.
The first manifold demonstrated that a fully functional 3D-printed Saab exhaust manifold was possible. The second shows that the concept can be repeated, refined and adapted to different combinations of engines and turbochargers.
The design philosophy remains consistent with what Joel explained when introducing the original manifold. Rather than focusing solely on peak horsepower, the geometry is intended to address real-world exhaust pulse behavior, heat retention and turbocharger response.
That approach emerged from Joel’s own experience chasing airflow limitations and cylinder-specific exhaust pulse issues on his high-power Saab projects. The resulting design process eventually led to a manifold architecture that could not easily be manufactured using conventional methods.
Metal additive manufacturing simply made those shapes possible.
A Glimpse of Saab Tuning’s Future
For now, the project remains a niche development aimed at serious Saab enthusiasts. Industrial metal printing is still expensive compared with traditional fabrication, and these manifolds are far removed from mass-market aftermarket parts.
Yet the direction is difficult to ignore.
Only a few years ago, the idea of ordering a custom-designed, stainless-steel, 3D-printed Saab exhaust manifold optimized for a specific turbocharger would have sounded unrealistic. Earlier this year, Joel completed multiple variants covering everything from stock-location TD04HL setups to modern Garrett and BorgWarner performance combinations.
Joel also notes that all currently shown manifold designs were created and printed earlier in 2026. Due to personal circumstances, no further development work is expected before the fall. While the project has already demonstrated what is possible with 3D-printed Saab exhaust manifolds, additional testing and future design work will have to wait until later this year.
The first manifold proved the concept. The second suggests the concept may have a future.
