3D Printing in Motorsport

Each year, the integration of 3D printing in F1 has grown, with teams leveraging this cutting-edge technology to accelerate their development processes like never before.

We delve into some of the most exciting 3D printing initiatives within F1, showcasing how teams and manufacturers are innovating with this technology. Out of the myriad examples available, we've selected six standout projects highlighting the transformative power of 3D printing in the sport. Join us as we explore these groundbreaking advancements and their impact on the world of Formula 1.

How Is 3D Printing Used In Motorsport?

3D printing serves several end goals in motorsports. It’s used everywhere, from the first stages of part and vehicle design to the manufacturing of the final on-vehicle components. After several decades, it can even bring long-forgotten cars back to the race track.

In 2017, McLaren took a significant step in advancing its car manufacturing capabilities by deepening its partnership with 3D printing giant Stratasys. By acquiring additional 3D printers from Stratasys, McLaren aimed to enhance its fused deposition modelling (FDM) technology to produce parts, speed up car development, and create heat-sensitive components more efficiently.

A pioneering innovation from this collaboration was McLaren's rear-wing flap. While the flap itself wasn't 3D printed, the lay-up tool used to mould its carbon fibre-reinforced composites was. This tool, produced on the Fortus 900mc Production 3D printer using ULTEM 1010 material, took three days to print. Designed to increase rear-wing downforce, this high-temperature composite structure helped shave off crucial tenths of a second per lap, allowing McLaren to adapt to circuit-specific downforce requirements and maximise performance quickly.

Fast forward to the 2023 season, and McLaren continues to leverage Stratasys 3D printing technology. This sustained use of cutting-edge 3D printing may be one of the key factors behind McLaren's impressive performance, positioning them as the second-fastest team heading into Formula 1's Summer Break.

The Alpine F1 Team (formerly the Renault F1 Team) is among the earliest adopters of 3D printing technology in the racing series. Since 1998, Alpine has utilised 3D Systems technologies, and their collaboration remains ongoing. Alpine employs a diverse array of 3D Systems printers, including SLA and SLS printers for research and development and design validation and metal 3D printers for manufacturing on-car parts.

Using 3D Printing For Moulds

Alpine also produces moulds for investment casting and exploring direct metal 3D printing. For instance, it printed a complex dampening coil from titanium. This 3D-printed component features thin, adjacent walls, resulting in weight reduction. The single-part digital design enabled Alpine to fit the component perfectly into the limited space within the gearbox main case.

Williams Racing, one of the most storied teams in Formula 1, is leveraging cutting-edge 3D printing technology to enhance the development of its front wings and other critical components during wind tunnel testing. This innovative approach is part of their ongoing efforts to stay competitive in the highly demanding world of motorsports.

Advanced 3D Printing Techniques

In 2021, Williams announced a new partnership with Nexa3D to expand its additive manufacturing capabilities. Previously partnered with German manufacturer EOS, Williams is now utilising NXE400 photo-curing resin printers and NexaX software to optimise the production and performance of its car parts. This new technology allows the team to iterate aerodynamic ideas more quickly, helping it close the gap to midfield competitors.

Williams Racing is not alone in adopting 3D printing technology. Many Formula 1 teams are exploring various applications of additive manufacturing to gain a competitive edge. For example, the BWT Alpine F1 Team uses numerous SLA and LPBF machines from 3D Systems for wind tunnel testing parts and various tooling needs. They often rely on materials co-developed with 3D Systems.

Other examples include metal parts produced by APWORKS and Additive Industries, as well as polymer components produced by Roboze. These advanced manufacturing techniques enable teams to rapidly prototype and refine designs, ensuring they remain at the forefront of performance and innovation.

Conclusion

In summary, 3D printing is revolutionising how F1 teams develop and test components, with Williams Racing leading the charge through its partnership with Nexa3D. As technology continues to evolve, we can expect even more groundbreaking advancements in motorsports.