F1 Additive Manufacturing Applications
Multiple Ways F1 Teams Apply 3D Printing to Motor Racing
In a sport where speed, weight reduction, and development cycles are crucial, the combination of 3D printing and F1 is not surprising.
Every year, the use of 3D printing in F1 racing expands, with multiple teams leveraging the technology to accelerate their development processes faster than ever before.
This article explores some of these 3D printing efforts and how teams and manufacturers integrate the technology into the sport.
There are many examples to choose from, but in the end, we highlight six projects that have taken place in F1 so far.
McLaren 3D Printed Rear Wing Mold
The composite layup tool for the McLaren MCL32 rear wing flap was produced using ULTEM1010 material on a Stratasys Fortus 900mc 3D printer.
In 2017, McLaren announced an expansion of its manufacturing relationship with 3D printing company Stratasys by purchasing more 3D printers.
The team had been using the company's Fused Deposition Modeling (FDM) printers to print parts, accelerate car development, and manufacture heat-sensitive parts, but wanted to increase manufacturing capabilities.
One of the many 3D printed upgrade parts showcased by McLaren was its rear wing flap.
While the race wing flap itself was not 3D printed, the layup tool used to mold the carbon fiber reinforced composite was 3D printed.
The tool was made on a Fortus 900mc Production 3D printer using ULTEM1010 material, and the printing took three days.
With this technology, McLaren was able to quickly change track-specific downforce requirements and ensure their cars performed optimally.
McLaren continued to use Stratasys 3D printers in the 2023 season, which may be one reason they had the second-fastest car during F1 races.
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 has utilized it to manufacture engine pistons.
The company believes this technology can not only help reduce car weight but also improve engine reliability.
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 rely instead on steel alloys that can better resist deformation and not fracture at extreme temperatures.
While steel alloys might be heavier, Ferrari can incorporate weight-reducing lattice designs, such as honeycomb structures, to reduce weight while maintaining the part's strength.
Ferrari isn't the only company exploring 3D printed engine designs, but it's one of the most vocal about it.
3TAM's 3D Printed Roll Hoop Structure
In recent years, the relationship between 3D printing and F1 has likely expanded.
In 2012, 3TAM (formerly 3TRPD) demonstrated the advantages of metal 3D printing to F1 by producing its own 3D printed roll hoop concept.
The roll hoop, made from Ti6Al4V and a custom lattice design from Within Technologies, reduced weight by 2 kilograms.
The design was optimized using WithinEnhanced software, including combining thin walls with an internal lattice structure to create the structural strength needed to protect the driver's head during vehicle rollover.
F1 teams provided positive feedback on the roll hoop, and it has since been incorporated into some F1 cars.
EOS Brake Pedal
When every gram matters, 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 manufacture a brake pedal and reduce its weight using its topology optimization software and LPBF printing technology.
The pedal, weighing only 178 grams, features a spiderweb-like design to ensure structural stability.
EOS states that it can further reduce the weight by 80 grams, producing functional parts as light as 98 grams.
As of 2021, these pedals were only demonstrative and not specified for competition. However, if F1 teams wished, they could test them to ensure compliance with FIA safety standards.
Alfa Romeo 3D Printed Brake Inlet for Wind Tunnel Testing
Sauber Alfa Romeo sought to use polymer laser sintering technology to manufacture and test its brake inlet designs. The company utilized this technology to iterate multiple brake inlet ideas faster than traditional manufacturing.
The team stated they enjoyed the flexibility and speed offered by 3D printing, which also allowed them to discover designs that ensured optimal car performance.
The development team printed using its proprietary HiPAC powder, a carbon-reinforced polyamide, 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 the competitive F1 development race.
Williams Uses 3D Printed Front Wing for Wind Tunnel Testing
One of the most famous F1 teams, Williams Racing, has been using 3D printing during wind tunnel testing to help develop its front wing and other parts.
Williams, which 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 concepts faster and attempt to close the gap with the midfield.