Case Studies of Additive Manufacturing in F1 Cars
How F1 Teams Are Adopting 3D Printing in Motorsports for Diverse Applications
In the world of motorsports, where speed, lightweight design, and shortened development cycles are paramount, the integration of 3D printing and F1 is a natural progression.
Today, the application of 3D printing in F1 cars is expanding annually, with many teams utilizing this technology to accelerate their development processes at an unprecedented pace.
This article explores case studies of 3D printing applications and how teams and manufacturers are incorporating this technology into motorsports.
Among numerous examples, we will introduce six prominent projects that have been implemented in F1 to date.
McLaren: 3D Printed Rear Wing Layup Tool
A composite layup tool for the McLaren MCL32 rear wing flap, manufactured using a Stratasys Fortus 900mc 3D printer and ULTEM 1010 material.
In 2017, McLaren announced an expanded manufacturing partnership with 3D printing giant Stratasys, adding more 3D printers to their operations.
The team had previously used Stratasys' Fused Deposition Modeling (FDM) 3D printers to produce parts, accelerate machine development, and manufacture heat-sensitive components, but they aimed to further enhance their production capabilities.
Among the many 3D printed improvements McLaren unveiled, the rear wing flap garnered significant attention.
While the flap itself, used in races, is not 3D printed, the layup tool used to mold the carbon fiber reinforced composite material was produced with a 3D printer.
This tool was printed in just three days using a Fortus 900mc Production 3D printer and ULTEM 1010 material.
This technology allowed McLaren to quickly respond to the downforce requirements of each circuit and optimize the car's performance.
McLaren continued to leverage Stratasys' 3D printers in the 2023 season, which is one of the reasons the team was able to perform at the highest level during F1 Grand Prix events.
Ferrari: 3D Printed Engine Piston
F1 fans might be surprised to hear that functional engine pistons are being produced with 3D printers in F1.
Ferrari has announced its exploration of metal 3D printing technology and the manufacturing of engine pistons using this technology.
The company is confident that this technology will contribute not only to lighter car bodies but also to improved engine reliability.
Specifically, Ferrari has been researching various steel alloy powders that can be used for 3D printed pistons.
The company aimed to transition from traditionally used aluminum alloy powders to steel alloys, which are more resistant to deformation and damage in extreme high-temperature environments.
While steel alloys tend to be heavier, they achieved weight reduction while maintaining strength by adopting lightweight lattice structures, including honeycomb designs.
Ferrari is not the only company exploring 3D printing for engine design, but it is one of the most proactive in sharing information about its efforts.
3TAM: 3D Printed Roll Hoop (Protective Structure)
In recent years, the relationship between 3D printing and F1 has deepened significantly.
In 2012, 3TAM (formerly 3TRPD) produced a unique 3D printed roll hoop concept, demonstrating the superiority of metal 3D printing to the F1 industry.
This roll hoop, made from Ti6Al4V (titanium alloy), achieved a 2kg weight reduction through a custom lattice design by Within Technologies.
Within Enhance software was used for the design, combining thin-walled structures with internal lattice structures to ensure the structural strength required to protect the driver's head in the event of a vehicle rollover.
F1 teams highly praised this roll cage structure, and it has since been adopted in some F1 cars.
EOS: Lightweight Brake Pedal
In the world of F1, where every gram of weight reduction can mean the difference between victory and defeat, teams are relentlessly pursuing lightweight designs, even down to the brake pedals.
EOS, a leading manufacturer of metal Laser Powder Bed Fusion (LPBF) 3D printers, demonstrated a technology that simultaneously achieves lighter and stronger pedals.
The company challenged its engineers to significantly reduce the weight of a brake pedal using topology optimization software and LPBF printing technology.
The finished pedal weighs just 178g and ensures excellent structural stability through its web-like design.
According to EOS, an additional 80g could be removed, making it possible to produce a functional part weighing as little as 98g.
As of 2021, these pedals were for demonstration purposes and not designated for actual race use, but F1 teams can test them for compliance with FIA safety standards.
Alfa Romeo: 3D Printed Brake Ducts for Wind Tunnel Testing
Sauber Alfa Romeo adopted Polymer Laser Sintering (SLS) technology for the design and validation of brake ducts. This technology allowed for faster iteration of multiple brake duct ideas compared to traditional manufacturing processes.
The team highly values the flexibility and speed offered by 3D printing, which helps them discover designs that push machine performance to its limits.
The development team used a proprietary HiPAC powder (carbon-reinforced polyamide) to create parts that combine lightness with high rigidity.
In addition to the cost savings from 3D printing, the manufacturing team was surprised by the time saved by being able to validate multiple development approaches in parallel.
Sauber plans to continue leveraging this technology to accelerate machine development and maintain high agility in the competitive F1 development race.
Williams: 3D Printed Front Wing for Wind Tunnel Testing
The prestigious F1 team, Williams Racing, continues to utilize 3D printing technology for wind tunnel testing in the development of components such as front wings.
Having previously collaborated with Germany's EOS, Williams announced a new partnership with Nexa3D in 2021, aiming to further expand its additive manufacturing capabilities.
The team adopted the NXE 400 Stereolithography (SLA/DLP) 3D printer and NexaX software to optimize the efficiency and performance of part production for their cars.
By integrating Nexa3D's technology, the team is accelerating the validation cycle for aerodynamic concepts and working to close the time gap with midfield competitors.