Wind tunnel testing is essential for
the aerodynamic development of
a Formula 1 race car.
leveraging our 3D Systems solutions to
produce 200 to 300 plastic parts per work
day.”
RACING TO THE FINISH
Once the development is approved,
the final parts are produced, often in
carbon fibre, using both conventionally
manufactured and 3D printed moulding.
“The Alfa Romeo Sauber F1 Team draws
on a variety of 3D Systems’ SLA materials
to produce tools for different applications.
For example, we laminate carbon parts
using tools produced in Bluestone
material and we use the Xtreme material
for vacuum casting tools to produce the
sealings,” says Hansen. Bluestone is a
stable engineered nano composite for high
stiffness parts such as wind-tunnel test
models, fixtures, jigs and tools, lighting
components, ‘under-the-hood’ automotive
parts and electrical components, while
Xtreme material is an ultra-tough grey
plastic that resists breakage and handles
challenging functional assemblies.
“Why do we 3D print the tools, instead
of using conventional tooling techniques?”
he asks. “The answer is easy – we get
the design complexity for free! This is
absolutely essential for parts like complex
duct systems.”
As Hansen points out, it takes a
winning team to succeed in Formula One
and the 3D Systems partnership with the
Alfa Romeo Sauber F1 Team “matches
the world’s most advanced additive
ON A MISSION
3D Systems’ SLS and SLA 3D printing technologies play a highly
significant role in the design and development of mission-critical
components for a whole range of mainstream industries, including
automotive, aerospace and healthcare.
Selective Laser Sintering (SLS) employs production-grade, standardsbased
thermoplastics to produce durable parts that meet and exceed
engineering requirements for strength, durability, heat, chemical
resistance and biocompatibility.
Free of the design limitations of conventional manufacturing
processes, such as injection moulding and CNC, engineers using SLS
can create innovative nylon parts that consolidate assemblies to reduce
complexity and increase reliability – without the need for tooling. For
the automotive and aerospace industries, this means that products
xxxxxx
manufacturing solutions with cutting-edge
automotive engineering”.
Phil Schultz, senior vice president,
general manager, on demand solutions and
plastics, 3D Systems, takes up the story.
“By increasing production throughput with
the addition of the 3D Systems’ ProX 800
SLA systems, Sauber can test more design
revisions and push the limits of race car
innovation. Formula One is the ultimate
proving ground for 3D printing and the
expertise we continue to acquire can be
applied to mainstream passenger vehicles,
as well as aerospace and other industries.”
In addition to using 3D Systems’
Additive Manufacturing for its own
prototyping and production requirements,
Sauber leverages the 3D printers for
are brought to market faster, supply chains are simplified and the final
vehicles themselves can incorporate lighter weight parts, which deliver
increased fuel efficiency.
Stereolithography (SLA) was invented by 3D Systems founder Chuck
Hull more than 30 years ago. Today, SLA 3D printing is regarded by many
as the best choice for producing large quantities of plastic parts with
extremely smooth surface finishes and high-resolution accuracy.
This is important not only for iterative prototyping – where multiple
part designs are quickly 3D printed, tested and revised to deliver better
products, faster – but also for manufacturing applications, such as rapid,
3D-printed casting patterns for automotive and aerospace parts where
complete precision is an absolute must.
More information at: https://uk.3dsystems.com.
18 www.ied.org.uk
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