The 2021 Formula One season has been nothing short of thrilling, both on and off the racetrack. Off the track, Formula One is experiencing remarkable growth, thanks to the widespread adoption of additive manufacturing. In this article, we’ll explore how teams like Alpine, Sauber, and Alfa Romeo are leveraging 3D printing technology to gain a competitive edge.
Alfa Romeo Racing’s Post-Processing Advancements
Alfa Romeo Racing, the Italian-Swiss Formula One team, has recently announced an exciting partnership with AM Solutions, the Italian 3D printing subsidiary of the Rossler Group. This collaboration aims to enhance the post-processing of 3D printed components used in their race cars.
As part of this partnership, Alfa Romeo Racing will receive three S1 systems from AM Solutions. These automated post-processing systems are designed specifically for 3D printed plastic and metal parts. They will play a crucial role in automating the de-powdering and cleaning of small to medium-sized components used in the C41 race car.
Fredrick Vasseur, Team Principal at Alfa Romeo Racing and CEO of Sauber Motorsport, highlighted the growing role of additive manufacturing in Formula One. He mentioned that every new iteration of their race cars incorporates more 3D printed parts, improving not only the cars’ performance but also the team’s overall efficiency and cost-effectiveness.
Sauber Engineering’s Venture into Classic Car Spare Parts
Sauber Engineering, a division of the Sauber Group that operates the Alfa Romeo F1 team, is leveraging its 28 years of experience in Formula One to enter the world of 3D printed classic car spare parts. They plan to establish a reverse engineering service catering to heritage vehicles.
This venture aims to address the global demand among vintage car enthusiasts for spare parts that are often challenging to find. Sauber Engineering has the capability to produce a wide range of components, from simple plastic covers to complete metal printed gearbox housings and even engine parts. Their expertise in additive manufacturing positions them as a valuable resource for classic car owners.
3D Printing in Formula One: A Game Changer
Formula One has been at the forefront of engineering technologies, with 3D printing playing a pivotal role in every team on the grid. For example, McLaren has had a four-year partnership with Stratasys, while 3D Systems has been a long-time partner of Alpine, formerly known as Lotus Renault. Williams Racing has worked with various 3D printing technology companies over the years.
The use of 3D printing has significantly reduced costs in Formula One. Last season’s Alfa Romeo F1 car, the C39, featured 143 3D printed parts, a number that has more than doubled for the 2021 model, the C41. With 304 printed components, the team has achieved an astonishing 90% reduction in costs, showcasing the potential of 3D printing in low-volume production.
Revolutionizing Wind Tunnel Testing
3D Systems and Alpine have joined forces to develop AcuRA Composite PIV (Particle Image Velocimetry), a material designed for wind tunnel testing. In Formula One, as well as in the broader automotive industry, wind tunnel development is crucial for achieving optimal aerodynamics and fuel efficiency.
AcuRA Composite PIV simplifies the preparation process, saving time while providing more accurate testing data. The material’s unique optical properties enable more reliable data collection during wind tunnel testing.
Pat Warner, Alpine F1 Team’s Advanced Digital Manufacturing Manager, emphasized the importance of their collaboration with 3D Systems. This material enhances the testing process, and it’s a game-changer for achieving better results in wind tunnel operations.
Get Involved in the Discussion
Which Formula One team are you supporting this season, and is their approach to 3D printing one of the reasons for your support? Share your thoughts in the comments section below, and let’s discuss how technology is reshaping the world of racing.
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