"When we decided to expand our SLA production capacity, we felt it was time to deepen our collaboration with 3D Systems. We also needed to expand our capacity. So it was only logical to replace some of the older SLA systems with higher throughput printers such as the ProX 800," says Christoph Hansen, Head of Additive Manufacturing at Sauber. "We primarily use the SLA solutions from 3D Systems for wind tunnel testing, but also for tools for laminating carbon parts or vacuum casting silicon parts."

Indispensable for wind tunnel tests

Wind tunnel tests are essential in the aerodynamic development of a Formula 1 racing car. For the tests in Sauber's ultra-modern in-house wind tunnel, a model of the vehicle is produced in 60 percent of its original size. Additive manufacturing techniques are predominantly used to produce this model. The SLS and SLA 3D printers are used for a wide variety of parts - from front wings, brake lines and chassis covers to engine covers, interior ducts and hand deflectors.

"This process cannot be compared with conventional manufacturing - manufacturing using processes other than 3D printing is out of the question. We need a large number of parts with excellent surface quality in the shortest possible time," says Reto Trachsel, Head of Aerodynamic Design at Sauber. "It has happened that our wind tunnel, which is also used by external companies, has been running around the clock and we have produced 200 to 300 plastic parts per working day."

Crossing the finish line with 3D-printed tools

Once the development has been approved, the final parts are manufactured. These are often made of carbon fiber materials and are produced either using conventional methods or 3D printing.

"The Alfa Romeo Sauber F1 Team uses different SLA materials from 3D Systems to produce tools for a wide range of applications," says Hansen. "The partnership between 3D Systems and the Alfa Romeo Sauber F1 Team brings together the world's most advanced additive manufacturing solutions with the most advanced automotive technology. By increasing throughput in production with the addition of the ProX-800 SLA printers, Sauber can now test even more design changes and continue to push the boundaries of innovation in racing," said Phil Schultz, Senior Vice President and General Manager, On-Demand Solutions and Plastics, at3D Systems. "Formula 1 is the ultimate proving ground for 3D printing. The experience we gain here can also be applied to the broader automotive industry, as well as aerospace and other sectors."

Technical services for external customers

Sauber not only uses 3D Systems' additive manufacturing technologies for its own prototyping and production, but also uses the 3D printers for its engineering service. This means that Sauber's expertise and its 3D-printed high-precision mockup models, jigs and fixtures, tools and series-produced parts are available to customers throughout Europe.

Hansen concludes: "Sauber Engineering enables a wide range of companies, large and small, to benefit from developments in motor racing. No matter whether we are optimizing the performance of our own F1 cars or helping our external customers to implement findings from prototype construction in series production."