McLaren Formula 1 racing deploys Stratasys additive manufacturing for the 2017 car

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Rear wing flap extension manufactured in carbon fibre-reinforced composites using a 3D-printer

Stratasys also explained that the large rear wing flap extension designed to increase rear downforce was manufactured in carbon fibre-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 (approximately 177°C) mould 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.

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