Formula One powerhouse McLaren Racing is responding to tighter vehicle production time and budget limits from the FIA by 3D printing tens of thousands of parts with large next-generation Neo800 stereolithography 3D printers from Stratasys.
McLaren produces up to 9,000 parts per year across numerous front and rear wing programs and large parts of the side bodywork and top-body. The race team reports significant strides in optimizing vehicle aerodynamics during wind tunnel testing thanks to the supreme accuracy of the parts printed on its five Neo800 systems. Beyond the qualitative aspect, part production time has also been dramatically reduced, with the team now able to produce certain large parts like scale model top-bodies in as little as three days.
It’s also less expensive. With the sport facing uncertain times and no income coming in during Covid, the FIA decided to bring the budget cap down from USD175 million to USD145 million for its first year of operation in 2021, then down to USD140 million for 2022 and USD135 million in 2023.
Using the fleet of in-house printers enables McLaren to manufacture all aerodynamic parts at its base in Woking, UK, which saves costs on subcontractors and the associated quality assurance QA process. The team can also 3D print jigs, templates, and small molds that would have previously been machined from metal billets. Not only does the speed of the Neo800 stereolithography process save considerable time, but it also saves on costly metal material by not wasting large amounts of swarf removed from the subtractive machining process.
“Stereolithography technology and the materials have evolved – changing the way we use it”, explains Tim Chapman, Head of Additive Manufacturing at McLaren Racing. “We do not just manufacture prototypes anymore; we now produce many full-scale components and full-size tooling.”
Wind tunnel testing is one of the primary applications where McLaren sees the most value with its next-generation Neo800s. The team uses 60% scale models to optimize the aerodynamic package and find more downforce – which provides more aerodynamic grip – and balance the car’s front and rear aerodynamic loads.
“Wind tunnel testing is still the gold standard when assessing how every surface works together, either as an assembly or as a complete car,” explains Chapman. “Our Neo series of 3D printers have helped us to dramatically reduce the lead times of our aerodynamic wind tunnel components and projects.”
Andy Langfeld, President EMEA, Stratasys, says: “Transformative value in 3D printing comes from being able to customize and tailor parts for specific applications quickly. In this case, McLaren has been able to dramatically shorten product development time and control costs with next-gen stereolithography technology from Stratasys that is combined with world-class Somos materials and our deep racing expertise,”