Additive Manufacturing Applications in F1 Racing
How F1 Teams Are Using 3D Printing in Motorsports
In a sport where speed, weight reduction, and development cycles are paramount, the synergy between 3D printing and F1 is no surprise.
Each year, the use of 3D printing in F1 cars expands, with multiple teams leveraging the technology to push their development processes faster than ever before.
This article explores some of these 3D printing efforts and how teams and manufacturers are integrating the technology into the sport.
There are many examples to choose from, but ultimately, we’ve highlighted six projects that have taken place in F1 to date.
McLaren 3D Printed Rear Wing Mold
The composite lay-up tool for the McLaren MCL32 rear wing flap was produced on a Stratasys Fortus 900mc 3D printer using ULTEM1010 material.
In 2017, McLaren announced an expansion of its manufacturing relationship with 3D printing company Stratasys by acquiring more 3D printers.
The team has been using the company's Fused Deposition Modeling (FDM) printers to print parts, accelerate car development, and manufacture heat-sensitive components, but wanted to increase its manufacturing capabilities.
One of the many 3D printed upgraded parts showcased by McLaren was its rear wing flap.
While the race wing flap itself isn't 3D printed, the lay-up tool used to mold the carbon fiber-reinforced composite is 3D printed.
The tool was produced on a Fortus 900mc Production 3D printer using ULTEM1010 material, with the print taking three days.
With this technology, McLaren was able to quickly adapt to track-specific downforce requirements and ensure their cars performed optimally.
McLaren continues to use Stratasys 3D printers in the 2023 season, which may be one of the reasons they have the second-fastest car in F1.
Ferrari's 3D Printed Piston
Some F1 fans might be surprised to hear that 3D printing has created a real engine piston.
Ferrari has openly discussed its exploration of metal 3D printing and how the company is leveraging it to manufacture engine pistons.
The company believes that the technology can not only help reduce the weight of the car but also improve the reliability of the engine.
Specifically, Ferrari has been exploring various steel alloy powders that can be used to manufacture 3D printed pistons.
The company hopes to move away from commonly used aluminum alloy powders and instead rely on steel alloys that can better resist deformation and not break at extreme temperatures.
While steel alloys may be heavier, Ferrari can incorporate weight-reducing lattice designs, such as honeycomb structures, to reduce weight while maintaining the part's strength.
Ferrari is not the only company exploring 3D printed engine designs, but it is one of the most vocal about it.
3TAM's 3D Printed Roll Hoop Structure
The relationship between 3D printing and F1 has likely expanded in recent years.
In 2012, 3TAM (formerly 3TRPD) demonstrated the benefits of metal 3D printing to F1 by producing its own 3D printed roll hoop concept.
The roll hoop was made from Ti6Al4V and featured a custom lattice design by Within Technologies, resulting in a weight reduction of 2 kg.
The design was optimized using WithinEnhanced software, incorporating thin walls with an internal lattice structure to generate the structural strength required to protect the driver's head during vehicle rollovers.
F1 teams provided positive feedback on the roll hoop, which has since been incorporated into some F1 cars.
EOS Brake Pedal
When every gram counts, F1 teams strive to reduce weight, even down to the brake pedal!
EOS, a leading manufacturer of metal Laser Powder Bed Fusion (LPBF) 3D printers, demonstrated its ability to not only reduce the weight of a pedal but also strengthen it in the process.
The company tasked engineers with finding a way to use its topology optimization software and LPBF printing technology to manufacture a brake pedal and reduce its weight.
The pedal weighed only 178 grams and featured a spiderweb-like design to ensure structural stability.
EOS states that it could further reduce the weight by 80 grams, creating a functional part weighing as little as 98 grams.
As of 2021, these pedals were only demonstration models and not specified for competition; however, if F1 teams desired, they could test them to ensure compliance with FIA safety standards.
Alfa Romeo 3D Printed Brake Duct for Wind Tunnel Testing
Sauber Alfa Romeo sought to use polymer laser sintering technology to manufacture and test its brake duct designs, leveraging the technology to iterate multiple brake duct ideas faster than traditional manufacturing.
The team stated that they enjoyed the flexibility and speed offered by 3D printing, while also allowing them to discover designs that ensured optimal car performance.
The development team used their proprietary HiPAC powder, a carbon-reinforced polyamide, for printing due to the material's lightweight and rigid properties.
The cost savings brought by 3D printing and the time saved by exploring multiple development avenues in parallel surprised the manufacturing team.
Sauber intends to continue using this technology as it helps the team develop vehicles faster and remain agile in F1's competitive development race.
Williams Uses 3D Printed Front Wing for Wind Tunnel Testing
Williams Racing, one of the most famous F1 teams, has been using 3D printing during wind tunnel testing to help develop its front wing and other parts.
Williams, previously partnered with German manufacturer EOS, announced a new partnership with Nexa3D in 2021 to help expand its additive manufacturing capabilities.
The team plans to use the NXE400 resin 3D printer and NexaX software to optimize the car's print production and part performance.
The team can now leverage Nexa3D's technology to iterate aerodynamic ideas faster and try to close the gap with the midfield.