This article introduces the Dutch racing team Van Amersfoort's use of 3D printing in Formula 3 and Formula 4 racing!
Motorsport has always been a breeding ground for technological innovation. Engineers in this sport work day and night, competing against top innovators from around the world in fields such as automotive, aerospace, and data analytics, to create faster, stronger, and more agile vehicles. The Van Amersfoort team is no exception.
This Dutch team competes in both Formula 3 and Formula 4, winning numerous races and championships. It has also helped top drivers like Charles Leclerc and Max Verstappen prepare for Formula 1. However, Van Amersfoort's success hasn't stopped them from seeking new ways to truly stay ahead of the competition. That's why the team started using 3D printing technology.
At the starting line
Last year, in preparation for the Formula 3 regional championships, Van Amersfoort Racing used a chassis from the renowned Italian manufacturer Tatuus, known for its stability and enhanced horsepower. Everything seemed to be going smoothly—except for a minor bump along the way.
Van Amersfoort Formula 3 Technical Director Remco Advocaat said, "We only received the car two weeks before the weekend race, and when it arrived at the workshop, we had no tools at all. In just two weeks, we needed to be ready for the first race."
Formula 3 cars require perfect tuning before they can hit the track; it's a precise science where a difference of even a tenth of a second can determine whether you're on the podium or suffer a crushing defeat. Therefore, with only two weeks until race day, Van Amersfoort was in a very difficult position.
Remco said, "This is where rapid prototyping technology helps us a lot. We can make tools in two days, which was not possible in traditional metal manufacturing."
By using 3D printers to develop custom tools, the team was able to utilize every possible moment to fine-tune the vehicles. For example, they created a rear-end alignment tool that was mounted on the taillights of a Formula 3 car. This allows mechanics to precisely adjust the car's wheels, ensuring they are perfectly aligned on the track.
Cable compatibility
The rear-end alignment tool uses carbon rods, with stretched metal wires serving as a reference point for the vehicle's center point. Therefore, accurately positioning these carbon rods is extremely important. Because standard materials such as polylactic acid (PLA) lack sufficient strength and stiffness, the team began experimenting with carbon fiber reinforcement materials produced by Clariant.
"Remco said, 'We've always used traditional materials for printing, but with Ultimaker Clariant's carbon fiber materials, the possibilities are endless. We are now able to find solutions that can withstand extreme working environments.'"
Clariant PA6/66 20CF is a nylon material containing 20% carbon fiber, offering excellent performance. Since the Ultimaker S5 uses an open-filament system*, printing with this material using the Ultimaker CC 0.6 print core is not a problem.
*Open-type filament 3D printers can use any filament that matches the machine's parameters, sourced from a variety of material suppliers. This gives users the opportunity to choose filaments suitable for their project needs, as well as suppliers that meet their material quality and cost requirements. In contrast, closed-type filament 3D printers lock users into a limited selection of filaments, typically supplied by the machine manufacturer.
Clariant also provided the team with custom PET-G cable . This cable serves as an "internal buffer" for the rear-end calibration tools, preventing scratches on the paint during tool installation. The fluorescent orange of PET-G matches the decals on the Van Amersfoort Racing Formula 3 car, giving tools such as the custom sidebar air blower a sleek, professional look that aligns with the team's aesthetic.
From spectator to champion
While the team's engineers were using the Ultimaker S5 to create advanced tools, other members of the Van Amersfoort Racing team were also beginning to see the possibilities of 3D printing.
"The concept of 3D printing is constantly evolving within the company," Remco said. "You can often see machinists requesting the use of specific 3D printing tools."
3D printing technology has enabled teams to tackle challenges and create solutions that were previously impossible. For example, a mechanic responsible for a car's front brakes created a simple tool rack that can be placed on the car's suspension. Now, during maintenance, every tool or component needed to assemble the vehicle is directly visible and within easy reach.
A real halo costs around €4,000 and is difficult to replicate using traditional manufacturing methods. The Van Amersfoort team used a 3D printer to create a halo from four relatively simple printed parts, then glued them together and wrapped it with carbon fiber sheets. This method produced a halo strong enough for use in simulators, which now allow drivers to experience realistic views of the track.
The Road Ahead
Van Amersfoort team engineers have improved efficiency and made life easier in the garage and pit lane by using tools, jigs, and fixtures created with 3D printers. The team is discovering new applications almost daily, pushing the boundaries of racing innovation with 3D printing and other technologies.
Remco said, "Given the sheer size of our F3 and F4 teams, the number of 3D printing applications is enormous. I can imagine large companies like automakers using 3D printing technology to produce a wide variety of tools."
This shows that 3D printing has a wide range of applications across various industries , and the demand will continue to grow .
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