【3D Printing Application】3D Printing Across Industries - Used in Motorsports!
This article features the Dutch team Van Amersfoort Racing, which uses 3D printing in Formula 3 and Formula 4 races!
Motorsports has always been a hotbed of technological innovation. Engineers in this sport work tirelessly, competing with global innovators from various fields like 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, winning multiple races and championships. It has also helped top drivers like Charles Leclerc and Max Verstappen prepare for Formula 1. However, Van Amersfoort Racing's success has not 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, while preparing for the F3 Regional Formula race, Van Amersfoort Racing adopted a chassis provided by 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 only received the cars two weeks before the race weekend," says Remco Advocaat, Technical Director of Van Amersfoort Racing F3. "When the cars arrived at the workshop, we had no tools whatsoever. We had to be ready for the first race in just two weeks."
Formula 3 cars must be perfectly tuned to hit the track, a precise science where a tenth of a second can be the difference between a championship podium and a devastating defeat. Thus, with only two weeks until race day, Van Amersfoort found itself in a tough spot.
Van Amersfoort Racing's garage
Remco states, "This is where rapid prototyping helped us immensely. We could produce tools within two days, which was impossible with traditional metal manufacturing."
By developing custom tools using a 3D printer, the team was able to utilize every possible moment to fine-tune the vehicles. For example, they created a rear alignment tool that attaches to the taillights of the Formula 3 car. This allows mechanics to precisely adjust the car's wheels, ensuring they are perfectly aligned on the track.
Filament Compatibility
The rear alignment tool uses carbon rods with stretched metal wires as benchmarks for the vehicle's center point. Therefore, accurate positioning of these carbon rods is extremely important. As standard materials like PLA lacked sufficient strength and rigidity, 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," Remco says. "We can now 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 was not an issue.
*Open filament 3D printers can manufacture with 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 typically supplied by the machine manufacturer.
3D printing materials used by Van Amersfoort Racing
Clariant also provided the team with custom PET-G filament. This filament is used for the "inner cushioning" of the rear alignment tool, preventing paint scratches when installing the tool. The fluorescent orange of the PET-G is an exact match to the decal color on the Van Amersfoort Racing Formula 3 car, making the tools (such as custom side air blowers) look sleek and professional, consistent with the team's aesthetic.
From Spectator to Champion
While the team's engineers were using the Ultimaker S5 to create advanced tools, other members of the Van Amersfoort Racing team also began to see the possibilities of 3D printing.
"The idea of 3D printing continues to evolve within the company," says Remco. "You often see mechanics requesting specific 3D printed tools."
3D printing technology has enabled the team to overcome challenges and create solutions that were previously difficult to achieve. For example, a mechanic responsible for the car's front brakes created a simple tool holder that rests on the car's suspension mount. Now, every tool or component needed for vehicle assembly during maintenance is directly visible and within reach.
3D printed tool holder allows mechanics easy access to tools
Van Amersfoort Racing's realistic internal racing simulators also incorporate this technology. These simulators provide drivers with the opportunity to familiarize themselves with the track and the car, as well as time to adapt to the "Halo." The "Halo" is a driver safety protection system consisting of a curved bar surrounding the cockpit, protecting the driver's head. The Halo can significantly 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 a 3D printer to create a Halo using four relatively simple prints, which were then glued together and wrapped with carbon fiber plates. This resulted in a Halo strong enough for use in the simulator, which now provides 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 a 3D printer to create a Halo using four relatively simple prints, which were then glued together and wrapped with carbon fiber plates. This resulted in a Halo strong enough for use in the simulator, which now provides drivers with a realistic view of the track.
The Road Ahead
Van Amersfoort Racing's engineers have improved efficiency by using tools, jigs, and fixtures created with 3D printers, making life easier in the garage and pits. The team is discovering new applications almost daily, pushing the limits of racing innovation with 3D printing and other technologies.
Remco says, "Given the large size of our F3 and F4 teams, the number of 3D printing applications is enormous. I can imagine that large companies, such as car manufacturers, can use 3D printing technology to produce many tools."
This demonstrates that 3D printing is versatile and widespread across various industries, and its demand will continue to grow.
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