【3D Printing Applications】3D Printing Across Industries - Used in Motorsports!
This article features the Dutch team Van Amersfoort using 3D printing in Formula 3 and Formula 4 racing!
Motorsports has always been a hotbed of technological innovation. Engineers in this sport work tirelessly, competing with global innovators from numerous fields such as automotive, aerospace, and data analytics, to create faster, stronger, and more agile vehicles. The Van Amersfoort Racing team is no exception.
This Dutch team competes in both Formula 3 and Formula 4, and has won numerous races and championships. It has also helped top drivers like Charles Leclerc and Max Verstappen prepare for Formula 1. But Van Amersfoort Racing's success hasn't stopped them from seeking new ways to truly stay ahead of the competition. This is why the team started using 3D printing technology.
At the starting line
Last year, in preparation for the F3 Regional Formula race, Van Amersfoort Racing adopted a chassis from the renowned Italian manufacturer Tatuus, known for its stability and enhanced horsepower. Everything seemed to be going smoothly—except for a small bump in the road. "We received the car only two weeks before the race weekend," said Remco Advocaat, Technical Director of Van Amersfoort Racing Formula 3. "When the car arrived at the workshop, we had no tools. In just two weeks, we needed to be ready for the first race."
Formula 3 cars must be perfectly tuned to hit the track, a precise science where a tenth of a second can determine the difference between standing on the champion's podium and the severity of failure. Therefore, with only two weeks until race day, Van Amersfoort was in a difficult position.
Van Amersfoort team garage
Remco said: "This is where rapid prototyping helped us a lot. We could manufacture tools in two days, which was impossible with traditional metal manufacturing."
By using 3D printers to develop custom tools, the team was able to maximize every possible minute to fine-tune the vehicle. For example, they created a rear alignment tool that attaches to the tail lights of the Formula 3 car. This allows mechanics to precisely adjust the car's wheels, ensuring they are perfectly tuned for the track.
Filament Compatibility
The rear alignment tool uses carbon rods, with stretched metal wires acting as a benchmark for the vehicle's center point. Therefore, accurately positioning these carbon rods is extremely important. Since standard materials like PLA lacked sufficient strength and stiffness, the team began experimenting with carbon fiber reinforced materials produced by Clariant.
"We've always printed with traditional materials, but with Ultimaker Clariant's carbon fiber material, the possibilities are endless," said Remco. "We are now able to find solutions that can withstand extreme working environments."
Clariant PA6/66 20CF, a nylon material containing 20% carbon fiber, performs perfectly. Since the Ultimaker S5 uses an open filament system*, printing this material with an Ultimaker CC 0.6 print core is not a problem.
*Open filament 3D printers can use any filament that meets the machine's parameters, from a variety of material suppliers. This gives users the opportunity to choose the filament that suits their project needs, while also being able to choose suppliers that meet their material quality and cost requirements. In contrast, closed filament 3D printers lock users into a limited selection of filaments, which are often provided by the machine manufacturer.
3D printed materials used by Van Amersfoort Racing
Clariant also provided the team with custom PET-G filament. This filament is used for the "internal bumper pads" of the rear alignment tool, preventing scratches to the paint when installing the tool. The fluorescent orange of PET-G is the exact same color as the decals on the Van Amersfoort Racing Formula 3 car, making tools (such as custom side bar air blowers) look sleek, professional, and consistent with the team's aesthetic.
From Spectator to Champion
While the team engineers were creating advanced tools using the Ultimaker S5, other members of the Van Amersfoort Racing team also began to see the possibilities of 3D printing.
"The idea of 3D printing continues to grow within the company," Remco said. "You often see mechanics asking for specific 3D printed tools."
3D printing technology has enabled the team to meet challenges and create solutions that were previously difficult to achieve. For example, the mechanic responsible for the car's front brakes created a simple tool holder that can be placed on the car's suspension. Now, every tool or part needed for vehicle assembly during maintenance is directly visible and within reach.
3D printed tool holder allows mechanics easy access to tools
This technology was also adopted in Van Amersfoort Racing's realistic internal racing simulators. These simulators provide drivers with the opportunity to familiarize themselves with the track and the car, and also give them time to adapt to the "Halo." The "Halo" is a driver safety protection system consisting of curved bars surrounding the racing car's cockpit, protecting the driver's head. The Halo can greatly reduce the probability of driver injury, but it can also affect their vision.
A real Halo costs about 4,000 euros and is difficult to replicate with traditional manufacturing methods. Van Amersfoort Racing used 3D printers to create a Halo from four relatively simple printed parts, which were then glued together and wrapped with carbon fiber sheets. The resulting Halo is strong enough for use in the simulator, which can now provide drivers with a realistic view of the track.
A real Halo costs about 4,000 euros and is difficult to replicate with traditional manufacturing methods. Van Amersfoort Racing used 3D printers to create a Halo from four relatively simple printed parts, which were then glued together and wrapped with carbon fiber sheets. The resulting Halo is strong enough for use in the simulator, which can now provide drivers with a realistic view of the track.
The Road Ahead
Van Amersfoort Racing engineers use 3D printers to create tools, jigs, and fixtures that improve efficiency, making life easier in the garage and pit. The team discovers new applications almost daily, leveraging 3D printing and other technologies to push the limits of racing innovation.
"Given the large size of our F3 and F4 teams, the number of 3D printing applications is enormous," Remco said. "I can imagine that large companies, such as car manufacturers, could use 3D printing technology to produce many tools."
This shows that 3D printing has widespread applications across various industries, and its demand will continue to grow.
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