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Additive Manufacturing in Formula 1®

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Additive Manufacturing in Formula 1® Additive Manufacturing in Formula 1® Dipl. Ing. Christoph Hansen «Head of Additive Manufacturing» The Sauber Group › History The Sauber Group More than 45 years of history in motorsports 1970 1982 1988 1989 Founding of the First assignment to Sauber becomes the Sportscar world PP Sauber AG build a “Le Mans official Mercedes – championship title Prototype” Benz factory team. and double victory at the 24h of Le Mans Page 3 © Sauber Motorsport AG | All Rights Reserved The Sauber Group More than 45 years of history in motorsports 1993 2003 2006 2010 Formula 1 entry Construction of the BMW takes over the Peter Sauber bought own wind tunnel. Sauber Team back the Sauber F1 Team Page 4 © Sauber Motorsport AG | All Rights Reserved The Sauber Group More than 45 years of history in motorpsorts 2016 2018 The story continues… Don’t miss the Alfa Romeo Sauber F1 Team’s first race in Melbourne on March 25, 2018 Longbow Finance Alfa Romeo buys the Team. becomes the teams title Sponsor. Page 5 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber › 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 Page 6 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber History › 1995 - 2007 The AM parts were purchased from external suppliers. › 2007 Set up of the own production Machines: 5 SLA 1 SLS › 2008 - 2018 Due to the rising demand of AM parts, the machine park had to be extended constantly. Machines: 6 SLA 6 SLS Page 7 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber History › 06/2017 The partnership wit AI was officially announced › 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 are going to be extended with an additional core and a storage module Page 8 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber Material Selection Plastic AM HiPAC Bluestone HPC Xtreme Parameter (SLS) 1) (SLA) 2) (SLA) 2) (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 1) HiPAC® developed by Sauber Engineering AG 2) Accura® Bluestone / HPC / Xtreme - 3DSystems product Page 9 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber Material Selection Metal AM AlSi10Mg Titanium Ti64 Parameter (DMLS) (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 Page 10 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber AM on the F1® car Page 11 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber Frontwing Benzing (Test) AM on the F1® car Roll Hoop HiPAC/ High Strength Aluminium Metalcoated/ Cooling Ducts Painted for Elecrtics HiPAC Brake duct scoops HiPAC Upright Covers Aluminium Page 12 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber AM on the F1® car Garage equipment HiPAC/Aluminium Exhaust and Turpo Pipes Inconel / Titanium Intercooler Pipe/ Radiator Interface Aluminium Page 13 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber AM in the F1® car production Page 14 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber AM in the F1® car production › Mold Production › Laminating cores › Trim and Bonding jigs Page 15 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber AM in Aerodynamics Page 16 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber Bodywork SLA/SLS Wishbone covers AM in Aerodynamics SLA Coolers and Internals (Pressure taps integrated) SLA Front and rear Wing parts Aluminium, SLA Floor (Pressure Taps integrated) SLA Page 17 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber Third Party Business Page 18 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber Third Party Business Fields › Prototyping › Serial Production › Spare part Production Main Applications › Automotive Industrie › Industrial Printing Industry › Space and Aviation Page 19 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber The Future of AM in the Sauber Team Page 20 © Sauber Motorsport AG | All Rights Reserved Additive Manufacturing at Sauber The Future of AM in the Sauber Group Become Center of Excelence in Additive Manufacturing › Setup engineering capabilities › Setup in depth technology know-how › Understand and control processes in depth › Setup in depth material know-how › Colaborations with universities Page 21 © Sauber Motorsport AG | All Rights Reserved Thank you very much ! Contact Information Christoph Hansen, Head of Additive Manufacturing Sauber Engineering AG, Wildbachstrasse 9, 8340 Hinwil, Switzerland Phone: +41 44 937 95 48 Mobile: +41 79 774 50 83 [email protected] Page 22 © Sauber Motorsport AG | All Rights Reserved.
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