HOW 3D PRINTING IS DRIVING INNOVATION IN F1

Red Bull Racing & Red Bull Technology ’s state of the art drone camera, which followed Max Verstappen’s car around Silverstone at speeds up to 220mph recently to capture unprecedented footage, is not the only innovation grabbing headlines in motorsport. 

In a sport known for pushing the boundaries of technological innovation, the adoption of 3D printing is delivering even greater progress for some of the world’s most advanced engineering teams. 

Way back in the 2010s, all ten constructor teams in F1 were using additive manufacturing to produce parts for their cars, taking advantage of ultra rapid prototyping, high precision, low volume production in all types of materials and complex shapes. In fact, the Renault F1 team purchased its first 3D printer as early as 1998. And as 3D printing technologies advance, the opportunities only increase. 

Today, the Mercedes-AMG PETRONAS Formula One Team uses processes including stereolithography (SLA) and multi jet 3D printing for rapid prototyping of wind tunnel parts, while McLaren Racing n has partnered with Stratasys , using its printer to make small mechanical adjustments to prototyped parts. 

Williams Racing has also used 3D printing to help develop the aerodynamics of its front wings and other components during wind tunnel testing. 

Additive manufacturing is not restricted to testing processes, however. 

3D printing is used widely for complex, specific tooling in F1 and we’re starting to see the technology being used in end-use parts, including exterior body parts, hydraulics management parts and engine components. The Alpha Romeo ORLEN F1 team has partnered with Additive Industries to produce end-use aerodynamic components for its cars, while Ferrari has used 3D-printed sensors on its race cars since 2022.

Other highlights of 3D printing use in F1 include: 

• 𝗠𝗰𝗟𝗮𝗿𝗲𝗻’𝘀 𝟯𝗗 𝗽𝗿𝗶𝗻𝘁𝗲𝗱 𝗺𝗼𝗹𝗱𝘀 𝗳𝗼𝗿 𝗿𝗲𝗮𝗿-𝘄𝗶𝗻𝗴 𝗳𝗹𝗮𝗴𝘀 – another result of McLaren’s long-standing partnership with Stratasys, the lay-up tool used to mold carbon fibre-reinforced composites is made with a 3D printer.
• 𝟯𝗗 𝗽𝗿𝗶𝗻𝘁𝗲𝗱 𝗲𝗻𝗴𝗶𝗻𝗲 𝗽𝗶𝘀𝘁𝗼𝗻𝘀 𝗳𝗿𝗼𝗺 𝗙𝗲𝗿𝗿𝗮𝗿𝗶 – helping to save weight and boost engine reliability, this one isn’t yet a reality, but Ferrari has spoken publicly about its potential.
• EOS 𝗯𝗿𝗮𝗸𝗲 𝗽𝗲𝗱𝗮𝗹𝘀 – 3D printer manufacturer EOS has developed ultra lightweight brake pedals which could be manufactured and, if tested to ensure they meet the FIA safety standards, further reduce the weight of cars, the company says.

3D printing is a perfect fit for F1, largely because of the low quantities and rapid turnaround needed on parts, often with multiple adjustments during the development phase. Expect to see more updates in the coming months and years as F1 constructor teams continue to adopt additive manufacturing technologies to drive progress.  

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