Additive Manufacturing in Motorsport: Not Just Prototyping!

The motorsport world is known for pushing technologies to their limits, requiring solutions that ensure speed, precision, and durability under extreme conditions. In this context, Additive Manufacturing (AM) has become an essential tool, not only for rapid prototyping but also for the production of functional and final components.

Throughout our “Motorsport Series,” we’ve explored how additive manufacturing is transforming this sector, enabling the creation of components that enhance performance, reduce weight, and optimize design. In this final article, we summarize all the key information, accompanied by practical examples demonstrating the potential of this technology.

Additive Technologies Used in Motorsport

Motorsport demands advanced additive technologies capable of producing robust and precise components. The main technologies employed include:

• Fused Deposition Modeling (FDM):

Ideal for producing large, strong parts using advanced materials such as carbon-filled Nylon12 and ULTEM. FDM is perfect for components requiring high thermal and mechanical resistance.

• Selective Laser Sintering (SLS):

Ideal for producing polymer parts with complex geometries and high precision. Materials such as PA11 and PA12 are used, offering excellent chemical and thermal resistance.

• Direct Metal Laser Sintering (DLMS):

A technology that allows the production of metal components in titanium, Inconel, and other advanced alloys. It’s used for active parts that must withstand high mechanical stresses, such as chassis and structural components.

• Stereolithography (SLA):

Used to produce aesthetic parts and detailed prototypes by curing resins with UV lasers.

 

Practical Examples of Additive Applications in Motorsport

During our series, we showcased several examples of how additive manufacturing can be effectively applied in motorsport. Here’s a recap of some of the most significant:

1. Passive Part in ULTEM 1010CG with FDM

This part, while not directly involved in mechanical functions, must resist chemical stresses (fuel and oil vapors) and constant temperatures over 200°C. It’s perfect for components that require thermal and chemical resistance without excessive mechanical effort.

2. WEC Car Airbox in ULTEM 1010CG

Also made using FDM technology, this airbox is designed to withstand high temperatures and internal pressures, with the potential to be produced in sizes up to 1 cubic meter—ideal for competition vehicles.

3. Spoiler in Nylon12 CF with Custom Finish

The spoiler, made from 35% carbon-filled Nylon12, is an example of how FDM technology can be used for structural components. Its thermal deflection is around 143°C, making it suitable for high-performance racing.

4. Brake Duct and Central Console in Nylon12 CF

Used for the airbox intake of a hypercar, this brake duct made from Nylon12 CF combines strength and lightness. The central console, meanwhile, was smoothed and painted with the team’s colors, showcasing the material’s versatility.

5. Supports and Frames in PA11 via SLS

These components, produced with SLS technology, were employed in a racing management system, ensuring precision and durability. PA11 is excellent for resisting environmental stresses and moderate mechanical forces.

6. Headlight Support Structure and Vent Duct in PA11

Using SLS technology, lightweight and durable components such as the headlight support and air duct for ventilation systems were produced.

 

                                                        

Benefits of Additive Manufacturing in Motorsport

Additive manufacturing is not just a production technology but a true revolution for the motorsport industry. Here are the main benefits it offers:

• Reduced Production Times: Unlike traditional methods, additive allows for a much faster transition from design to production.

• Cost Reduction: With additive, there’s no need for costly tooling, making the production of small batches or unique parts more economical.

• Flexibility and Customization: The ability to create complex and custom geometries without the limitations imposed by traditional manufacturing methods is a significant advantage. A single system can produce parts with various mechanical and geometric properties.

• Precision and Repeatability: Additive technologies ensure high precision and the ability to reproduce identical components quickly and efficiently. Furthermore, with 3D scanning and reverse engineering technologies, part quality can be further enhanced.

Choosing the Right Materials

Material selection is crucial to the success of additive manufacturing in motorsport. Among the main options are:

• Composite Plastics: Such as carbon-filled Nylon12, which offers an excellent combination of lightness and strength.

• Metals: Such as titanium and Inconel, ideal for applications requiring high mechanical and thermal resistance.

• Biocompatible and Flame-Retardant Plastics: Such as ULTEM, used for parts that must withstand high temperatures or meet specific safety requirements.

 

Conclusion

Additive manufacturing has proven to be a fundamental technology in motorsport, not just for prototyping but also for producing highly performing final parts. The ability to produce complex, customized parts using advanced materials makes this technology indispensable for improving the performance of race cars.
Considering these points, it is essential to collaborate with experts like Due Pi Greco, who can guide you in selecting the most suitable solution and fully leveraging this technology. Only in this way can the maximum benefits of additive manufacturing be achieved, turning ideas into tangible and high-performing results.