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The paper is aimed at investigating backpressure and backpressure variation of three way catalysts (TWC). Results presented show that backpressure variation is influenced by measurement error, substrate dimensional variation, and washcoat thickness. A broad range of anticipated washcoat differences between coaters is also considered. Results provided shows that Delphi high-flow FlexMetal catalyst achieves optimum emissions control with up to 40% less backpressure, leading to 5% additional torque on a 3.2 L engine.