Additive Manufacturing in Formula 1 · Additive Manufacturing in Formula 1 ... › AM in...

Additive Manufacturing in Formula 1®

Dipl. Ing. Christoph Hansen «Head of Additive Manufacturing»

The Sauber Group› History

© Sauber Motorsport AG | All Rights Reserved

The Sauber Group

More than 45 years of history in motorsports

1970 1982 1988 1989

Founding of thePP Sauber AG

First assignment to build a “Le Mans Prototype”

Sauber becomes the official Mercedes –Benz factory team.

Sportscar world championship title and double victory at the 24h of Le Mans


The Sauber Group

More than 45 years of history in motorsports

2003 2006 20101993

Formula 1 entry Construction of the own wind tunnel.

BMW takes over the Sauber Team

Peter Sauber bought back the Sauber F1 Team


The Sauber Group

More than 45 years of history in motorpsorts

20182016

Longbow Finance buys the Team.

Alfa Romeo becomes the teams title Sponsor.

The story continues… Don’t miss the Alfa Romeo Sauber F1 Team’s first race in Melbourne on March 25, 2018


› Development of AM at Sauber› AM on the F1® car› AM in the production of the race car› AM in aerodynamics› Third party business› The future of AM in the Sauber Team

Additive Manufacturing at Sauber



History

› 1995 - 2007 The AM parts were purchased from external suppliers.

› 2007 Set up of the own production

Machines: 5 SLA1 SLS

› 2008 - 2018 Due to the rising demand of AM parts, the machinepark had to be extended constantly.

Machines: 6 SLA6 SLS



History

› 10/2017 Start of the set up of the new Metal AM Center

› Today Two Additive Industries MetalFab1 Basic Systems are implemented successfully.

› Near Future Both MetalFab1 aregoing to be extendedwith an additional coreand a storage module

› 06/2017 The partnership wit AI was officiallyannounced


ParameterHiPAC

(SLS) 1)

Bluestone

(SLA) 2)

HPC

(SLA) 2)

Xtreme

(SLA) 2)

Density sintered at 25°C approx. 1,2g/cm³

Density solid at 25°C 1.78g/cm³ 1.61g/cm³ 1.19g/cm³

E module bending 7327MPa 8300 - 9800 MPa 9000-9700MPa 1520 - 2070MPa

Flexural strength 132MPa 124 - 154 MPa 137-157 MPa 52 - 71 MPa

E module tensile force 8304MPa 7600 - 11700MPa 8700-1200MPa 1790 - 1980 MPa

Tensile strength 85MPa 66 - 68 MPa 66-89MPa 38 - 44MPa

Crack expansion 2.7% 1.4 - 2.4 % 0.8-1.9% 14-22%

Melting point 172-176 °C

Heat resistance ca. 170°C 54°C

Glass transition temp. 71 - 83 °C 62-73°C

2) Accura® Bluestone / HPC / Xtreme - 3DSystems product1) HiPAC® developed by Sauber Engineering AG


Material Selection Plastic AM


ParameterAlSi10Mg

(DMLS)

Titanium Ti64

(DMLS)

Relative density >99.5% >99.5%

Absolute densitiy 2.67 g/cm3 4.43g/cm3

Ultimate tensile strength horizontal 400 MPa 950 MPa

Ultimate tensile strength vertical 400 MPa 950 MPa

Yield strength horizontal 200 MPa 880 MPa

Yield strength vertical 230 MPa 880 MPa

Elongation at break horizontal 3% 7%

Elongation at break vertical 3% 7%

Youngs modulus horizontal 70 GPa 100 GPa

Youngs modulus vertical 65 GPa 100 GPa

Hardness 100 HV 400 VV


Material Selection Metal AM



AM on the F1® car


Additive Manufacturing at Sauber FrontwingBenzing (Test)

HiPAC/Metalcoated/

Painted

Brake duct scoopsHiPAC

Roll HoopHigh Strength Aluminium

AM on the F1® car

Cooling Ductsfor Elecrtics

HiPAC

Upright CoversAluminium



AM on the F1® car

Exhaust andTurpo Pipes

Inconel / Titanium

Intercooler Pipe/Radiator Interface

Aluminium

Garage equipmentHiPAC/Aluminium



AM in the F1® car production



AM in the F1® car production

› Mold Production › Laminating cores › Trim and Bonding jigs



AM in Aerodynamics



AM in Aerodynamics

BodyworkSLA/SLS

Front and rear Wing parts

Aluminium, SLA

Wishbone coversSLA

Coolers and Internals(Pressure taps integrated)

SLA

Floor(Pressure Taps integrated)

SLA



Third Party Business



Third Party Business

Fields

› Prototyping› Serial Production› Spare part Production

Main Applications

› Automotive Industrie› Industrial Printing Industry› Space and Aviation



The Future of AM in the Sauber Team



The Future of AM in the Sauber Group

› Setup engineering capabilities

› Setup in depth technology know-how

› Understand and control processes in depth

› Setup in depth material know-how

› Colaborations with universities

Become Center of Excelence in Additive Manufacturing


Thank you very much !Contact Information

Christoph Hansen, Head of Additive ManufacturingSauber Engineering AG, Wildbachstrasse 9, 8340 Hinwil, Switzerland

[email protected]

Phone: +41 44 937 95 48Mobile: +41 79 774 50 83

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