McLaren Formula 1 Racing Deploys Stratasys Additive Manufacturing to Improve 2017 Car Performance
April 07 2017 - 3:00AM
Business Wire
- Stratasys FDM and PolyJet 3D Printing
Solutions are being used to produce final 3D printed race-ready
parts for the new McLaren MCL32 race car, as well as manufacturing
tooling to advance production
- 3D printing will also be used at
trackside to produce parts and tooling on demand for immediate
evaluation during tests and races
- Goal is to bring new car developments
earlier by moving from idea to component in a shorter
timeframe
McLaren Racing is expanding its use of Stratasys (Nasdaq: SSYS)
3D printing to produce components for its 2017 Formula 1 MCL32 race
car with the goal of accelerating design modifications and reducing
weight to increase performance.
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Hydraulic line bracket for the McLaren
MCL32 race car, 3D printed on a Stratasys FDM 3D Printer using
Nylon12CF material (Photo: Stratasys)
Some of the 3D printed parts designed to improve performance
which have been applied to the 2017 race car include:
- Hydraulic Line Bracket McLaren
Honda has 3D printed a structural bracket to attach the hydraulic
line on the MCL32 race car using Stratasys FDM technology,
leveraging a Fortus 450mc Production 3D Printer with carbon-fiber
reinforced nylon material (FDM® Nylon 12CF). The bracket was
produced in just four hours compared to an estimated two weeks to
create using traditional manufacturing processes.
- Flexible Radio Harness Location
BootA new 2-way communication and data system was recently
added to the MCL32 race car but the cable proved distracting to the
driver. Taking advantage of the Stratasys J750 3D Printer’s ability
to print in flexible materials, McLaren designed and 3D printed a
rubber-like boot to join the harness wires for the communication
system. Three different designs were iterated and 3D printed in one
day and the final component was 3D printed in just two hours which
allowed the comfortable radio harness assembly to be used in the
first Grand Prix race of the 2017 season.
- Carbon Fiber Composite Brake Cooling
Ducts To efficiently control the brake component temperatures,
McLaren Honda 3D printed sacrificial tools to create hollow
composite brake cooling ducts. The wash-out cores were 3D printed
using ST-130 soluble material, developed specifically for the
application, and then wrapped with carbon-fiber reinforced
composite material and autoclave-cured at elevated temperatures.
The final result is a tubular structure with very smooth internal
surface finishes to ensure the required airflow to brakes, whilst
maintaining maximum aerodynamic and car performance.
- Rear Wing Flap A large rear wing
flap extension designed to increase rear downforce was manufactured
in carbon fiber-reinforced composites using a 3D printed lay-up
tool produced on the FDM-based Fortus 900mc Production 3D Printer.
The team 3D printed the 900mm wide, high temperature
(>350°F/177°C) mold in ULTEM 1010 for the autoclave-cured
composite structure in just three days, saving time in a critical
limited testing period.
“We are consistently modifying and improving our Formula 1 car
designs, so the ability to test new designs quickly is critical to
making the car lighter and more importantly increasing the number
of tangible iterations in improved car performance. If we can bring
new developments to the car one race earlier - going from new idea
to new part in only a few days – this will be a key factor in
making the McLaren MCL32 more competitive. By expanding the use of
Stratasys 3D printing in our manufacturing processes, including
producing final car components, composite lay-up and sacrificial
tools, cutting jigs, and more, we are decreasing our lead times
while increasing part complexity,” said Neil Oatley, Design and
Development Director, McLaren Racing Limited.
To further accelerate design and manufacturing cycles, McLaren
Honda will be bringing a Stratasys uPrint SE Plus to track testing
and races on-site, enabling the team to produce parts and tooling
on demand.
“Formula 1 is one of the world’s best proving grounds for our
additive manufacturing solutions. As the Official Supplier of 3D
Printing Solutions to the McLaren-Honda Formula 1 team, we are
working closely together to solve their engineering challenges in
the workshop, in the wind-tunnel, and on the track. We believe that
this, in turn, will enable us to develop new materials and
applications that bring new efficiencies and capabilities to
McLaren Racing and other automotive designers and manufacturers,”
said Andy Middleton, President, Stratasys EMEA.
About McLaren:New Zealand racing driver Bruce McLaren
founded the McLaren team in 1963. At Monaco in 2016, McLaren
celebrated 50 years of racing in Formula 1. Since 1966, when it
entered its first Formula 1 race, McLaren has won 20 world
championships and over 180 grands prix. It is now globally renowned
as one of sport’s most successful competitors and as one of the
world’s most illustrious high-technology brands.
The McLaren Technology Group has grown to encompass much more
than just grand prix racing: McLaren produced the 1990s’ original
supercar, the McLaren F1, and, with the launch of McLaren
Automotive, has gone on to introduce a series of high-performance
cars, including the ground-breaking McLaren P1™.
McLaren Applied Technologies develops strategic business
partnerships that harness our expertise in high-performance design,
performance-management and simulation systems. It also develops,
builds and services control units for the entire Formula 1, Indy
Car and NASCAR grids.
The McLaren-Honda team campaigns the 2017 FIA Formula 1 World
Championship with double world champion Fernando Alonso and Belgian
rookie Stoffel Vandoorne, who scored points on his race debut for
McLaren-Honda, in a one-off performance at the 2016 Bahrain Grand
Prix.
About Stratasys:For more than 25 years, Stratasys
Ltd. (NASDAQ:SSYS) has been a defining force and
dominant player in 3D printing and additive manufacturing – shaping
the way things are made. Headquartered in Minneapolis, Minnesota
and Rehovot, Israel, the company empowers customers across a broad
range of vertical markets by enabling new paradigms for design and
manufacturing. The company’s solutions provide customers with
unmatched design freedom and manufacturing flexibility – reducing
time-to-market and lowering development costs, while improving
designs and communications. Stratasys subsidiaries include MakerBot
and Solidscape, and the Stratasys ecosystem includes 3D printers
for prototyping and production; a wide range of 3D printing
materials; parts on-demand via Stratasys Direct Manufacturing;
strategic consulting and professional services; and the Thingiverse
and GrabCAD communities with over 2 million 3D printable files for
free designs. With more than 2,700 employees and 1,200 granted or
pending additive manufacturing patents, Stratasys has received more
than 30 technology and leadership awards. Visit us online at:
www.stratasys.com or http://blog.stratasys.com/, and follow us on
LinkedIn.
Stratasys is a registered trademark of Stratasys Ltd. and/or its
subsidiaries or affiliates.
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McLaren Racing Media
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FrangipanePress office
managersilvia.hoffer@mclaren.comorStratasys Media ContactsArita Mattsoff –
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