the evolution of force TECHNIQUES 3D printing on Formula 1 teams can quickly rely on it to develop their cars for the championship, which is the most prominent arena for testing new and faster technologies.
The benefits of 3D printing technology at the production level are almost endless, starting with the ability to build prototypes of automobile parts with extraordinary speed, in addition to the high accuracy of implementation and the ability to form patterns and geometric shapes that are very complex. and difficult to achieve in traditional or even programmed production techniques Not to mention the low production cost of these parts.
Of course, Formula 1 is not the only motorsport that has relied on “additional production” technologies, but the growing use of 3D printers can be seen in the IndyCar Championship, World Rally Championship, Formula 2, Formula 3 and World. Formula E Championship for electric cars.
However, as Formula 1 is the “unofficial” leader of all advances and technical development in the world of motorsport, it was the first to rely on 3D printers and their most intensive user.
History of 3D printing in Formula 1
As mentioned above, Formula 1 has historically been the first to adopt new technologies that contribute significantly to making cars faster, stronger and lighter. The presence of 3D printing technology is not entirely new to Formula 1 and it may surprise some that the first 3D printer purchased by Renault was in 1998, but of course the use of “additional production” technologies as we know it today did not begin . behave in an upward trend until the beginning of the last decade.
The idea of the fast prototype caught the interest of the technicians and engineers of the Formula 1 teams, and this is exactly what they were looking for. To be successful in Formula 1, you must always strive to develop your car to be faster than your competitors, and all you have to do is try to record faster lap times, and that is a task that involves technique, technical, engineering and administrative development it involves.
The urgent need to repeat the production of car parts for teams was a daunting challenge, and here came 3D printing. One of the most important features this technology offers is the ability to quickly implement and print a prototype and then test it in the wind tunnel, and if teams need to modify it, the team quickly adjusts the design and then tests it again. . When the part meets the required specifications, 3D printers are used to produce the final product.
How do 3D printing technologies work alongside other production methods?
It is also known that the most important technology used in manufacturing, which has spread widely in the decades that witnessed a major industrial renaissance in the world, is production by injection or using programmed machines (CNC). What was impressive is that 3D printing was able, in a short period of time, to challenge these methods and prove itself at record speed as a method adopted in the world’s largest factories.
This is all because of the benefits that 3D printing offers and was exactly the last piece of the puzzle that every engineer in the world was looking for. This technology allows printing a small number of parts very quickly, unlike other methods that usually require more time and financial resources. It is also capable of producing parts with a high degree of complexity, which can not be realized using traditional methods.
For a sport that changes rapidly from one race to the next, it all has to do with the design and production of intricate parts. In addition to all this, here comes the role of software that contributes a lot to the so-called spatial optimization techniques. Here the engineers design the piece so that it is shaped in such a way as to reduce the weight as much as possible by being based on complex mathematics. matter distribution equations, imagine how this can play a big role in a high speed car like a Formula 1 car!
Overall, this technology fulfilled the dream of every manufacturing engineer worldwide, which is the magic ratio approach, which expresses the time taken for the piece produced.
However, 3D printers can not completely replace plastic injection molding machines, as the latter offers a more mature technology today and is able to use a wider range of types of plastic materials. Therefore, 3D printing technology can be considered complementary to the production of plastic injection machinery.
As for metal, through 3D printing, parts can usually be produced close to the final shape, and thus finished by programmed machines. The advantage of 3D printing here is that it can perform cuts that can be constrained by the use of programmable classifiers or lathes.
In summary, at the present time, no production method can be ruled out, but the optimal benefit is to achieve integration between these methods, to achieve greater productivity and efficiency.
What 3D printing technologies are used in Formula 1?
It can be said that current Formula 1 cars contain a lot of 3D printed parts. As we can expect, the field is open for Formula 1 engineers to use any technology they see fit. They do not rely on just one technique, but combine two or three of these techniques.
One of the first methods that became popular in 3D printing is fusion deposition modeling. This method allows fast modeling. Although modern plastics such as (nylon) are preferred for use in this method, it has recently been observed that the use of high performance polymers such as ketone polyester has increased because it is considered resistant to high temperatures, which can reach up to 2600 degrees. Celsius, which is very close to the operating temperature of the engine.
However, the use of this method is limited because these manufactured parts do not have the ability to be used to support functional parts, and you can therefore rely on the production of cooling channels or some electronic parts.
Stereolithography, a method in which a model builds one layer at a time by treating resin, which hardens after being exposed to light, is used to obtain complex parts.
However, this method is only used to produce parts that are not subject to significant forces and loads. For this reason, the world’s leading material factories are working to produce materials that can withstand different forces and can be used for this method.
Several 3D printing manufacturers have teamed up with the Renault and Williams teams to develop a new ceramic-filled epoxy, which is then printed in 3D for specific applications. Today, this method has been widely adopted by Formula 1 to produce wind tunnel test parts for all Formula 1 teams.
Currently, however, the most common method in Formula 1 is the powder formation technique, e.g. Selective laser sintering or direct sintering of metals by laser. This technology has an advantage over other technologies in that it can make symmetrical and stable parts and save more time.