Solution Brief McLaren increating thefuture ofmanufacturing. any businessthatisready tofuelgrowth can benefitfrom additivemanufacturing. Indoingso,youcanjoin while thesestoriesfocuson F1racingexamples,theprinciplesapplyacross multipleindustries.Virtually The followingpageshighlightMcLaren’s application ofAMtoacceleratetimelinesandreduce cost.But enterprises onhowtomaintaintheleadintheirownindustry. their questtoreach thewinner’s circle. Usingtools likeAM,F1racinghasbecomeaninspirationtoother The competitivenature ofFormula1(F1)racingpushesteamstodevelopthebest solutionspossiblein to pushitsuseofadditivemanufacturing(AM)thenext level. success relies onstate-of-the-arttechnology, soitwas nosurprisewhenMcLaren teamedupwithStratasys manufacturing technologytosolveuniquechallenges that honeitscompetitiveedge.McLaren Racing’s Since itsfoundingbyBruceMcLaren in1963,McLaren Racinghasconsistentlybeenattheforefront of HowAnd Can Lessons These Apply to Your Industry Makes McLaren GoFaster How 3DPrinting Production Director McLaren Director Production Pier Thynne manufacturing.” PolyJet and of FDM forefront the at us keeps Stratasys with partnering and different no is printing 3D performance. sustained and success to our fundamental is technologies latest of the abreast Keeping software. telemetry and Units Control Electronic F1 the in as used such today technologies of several innovation the Leading years. 50 last F1 the the for in world innovation in aleader been has “McLaren

Solution Brief 2 but alsoavoiding theadditionofexcess weight. adhesive, safeguarding againstaninsufficient amount can refine thetechniquewithrightamountof thisinsight,McLaren technicians materials. With bond joint,somethingthat’s notpossiblewith opaque together andprovides visibilitytotheintegrityof how theadhesivespreads whenpartsare pressed 1 through 4.Theclearmaterialletstechnicianssee to practicethebondingprocess, showninFigures McLaren 3Dprintedclearsurrogate suspensionparts In acleverexampleofusingclear3Dprintingmaterial, adhesive isnotanoptioneither. the otherteamsachancetopullahead.Too little Too muchadhesiveandthecarwillbeslower, giving features ofthecar’s suspension are bondedtogether. are meticulousintheirapproach forhowload-bearing reason, it’s crucialforengineerstomakesure they the driverisofutmostimportanceaswell.Forthis McLaren teamhastowatchoutfor. Thesafetyof simply cuttingweightisnottheonlything In F1racing,everygramofweightiscritical.But Compromising Safety Ingenious Weight SavingsWithout Prototyping model. suspension printed 3D the to adhesive the of 1-Application Figure and R&D Figure 2 - thetogether. Assembling parts Solution Brief 3 Design &Development Director McLaren Oatley Neil less wastage.” less personnelinvolved. Lesstime,fewerpeople,less material, metal orpolymer allows ustoachieveacomponent quicklywith end fitting.Usingadditivemanufacturing, ratherthanmachining between acompositesuspension wishbone anditsmatingmetal “This toolallowsustoquicklyverify thebondingprocess integrity this volumequicklyaddsup. be ascritical,inatraditionalmanufacturingscenario a fewgramsperpartonseveralracecarsmightnot costs andanenlargedenvironmental footprint.While wasted inproduction, thecompanyincursincreased manufacturing world.Anytimerawmaterialsare These lessonsalsotranslatetothebroader difficulty ofinspectingunseenadhesivejoints. driving outbottom-linecostsandsolvingthe McLaren finetunethemanufacturingprocess, Using AMforinnovativesolutionslikethishelps before thefinalcomponentsenterproduction. to ensure theirbondingprocesses are accurate successfully usedtransparent 3Dprintedtestparts on theStratasysJ850™PolyJet™printer, McLaren By takingadvantageoftheVeroUltraClear™ material others. in adhesive much too and areas some in distribution adhesive –poor results the show parts clear 3-The Figure on the J850. the on VeroUltraClear in printed models test suspension 5 – Wishbone Figure excellent coverage and no waste. no and coverage excellent with pattern adhesive optimized the showing test 4-Another Figure Solution Brief 4 finishing partsforthewind tunnelandallowsmore time fordesigningandtesting. can varythestiffness ofdifferent regions ofthemodel.Thisadjustabilityreduces timespentproducing and tunnel tofindidealsolutions withouthavingto rebuild theparts.UsingGrabCADPrint™software, engineers The flexibilityofcertainPolyJet materialsallowstheteamtomakesmallmechanical adjustmentsinthewind offers somethingothertechnologiescannot–flexibleanddurableparts. technology thiswaygivesMcLaren theabilitytonotonlyreduce timefrom initialdesigntophysicalpart,it results inarace-ready carfasterthantestingiterationsonfullproduction vehiclecomponents.UsingPolyJet research. Thetechnicalteamusesthemtomakesmallmechanicaladjustmentsprototyped parts.This The J850printergivesMcLaren awaytocreate highresolution windtunnelmodelsforaerodynamic Additive ManufacturingintheWindTunnel Prototyping tunnel. wind the in test under designs F1 car McLaren’s of 6-One Figure and R&D Solution Brief 5 valuable time. and evaluationprocess withAMsaves product presentation, acceleratingthedesign getting ready forthenextraceorweek’s deadlines, regardless ofindustry. Whether have asignificantimpactontightproduction using traditionalmanufacturingmethods Prototyping andtestingnewcomponents portions ofthemodel. as colorormechanicalbehaviortoindividual user assigncustommaterialproperties such software. Thestraightforward interfaceletsthe Stratasys’ GrabCADPrintbuildpreparation or assemblyofSTLscanbeloadedinto Figure 7showshowamulti-bodyCADfile colors. separate in shown with are Sections (hardness) values analysis. Shore aerodynamic different their for parts durometer variable uses McLaren how illustrates screenshot Print GrabCAD 7-This Figure Executive Director, Operations,McLaren Racing Piers Thynne factory too.” not onlyonthetrackbutin is aconstantraceagainsttime parts ofthecartochange.It we expect85%ofthedesigned to thefinalraceinAbuDhabi, race oftheseasoninAustralia key. From thetraditionalfirst so speedofproduction isreally is upgradedevery15minutes, parts andonaverage,onepart is madeupofaround 16,000 as itisonthetrack.AnF1car “Speed isascrucialoff thetrack Solution Brief 6 overall performanceandreducing expenses. components intimeforthenextrace,increasing workflow, McLaren isableto replace critical traditional counterparts.Through animproved approximately 25%incostcompared totheir for thenextweek’s race.3Dprintingsaved optimized, 3Dprintedpartsontheirvehicle numerous races,engineerswere abletohave of racingwithinadequatepartsontheircarfor previously took29daystocomplete.Instead to physicalpartinjustfivedays.Thisphase and 9,McLaren wasabletogofrom CADmodel In thisparticularexampleshowninFigures 8 worth it. afforded by3Dprintingmakestheextraweight in alighterpartsomecases,thetimesavings rigidity. Althoughtraditionalcompositesmayresult resulting inpartswithexceptionalstrength and thermoplastic containschoppedcarbonfiber, 12CF (carbonfiber)material.Thiscomposite to employ3Dprintinginstead,usingFDM light butincredibly strong andstiff ledMcLaren partsthatarematerial. Theneedforalternative make newlay-uptoolsandcure thecomposite fabricate thesepartsduetothehoursrequired to however, there’s simplynotenoughtimeto they’re lightweightbutstrong. Insomecases, for aerodynamic partsoftheir racecarsbecause Like otherraceteams,McLaren usescomposites Faster TimeFrom thePrinter totheCar Parts Production 3D Printed

® Nylon up to a carbon fiber lay-up assembly. lay-up fiber acarbon to up mated vanes) and (scoop part printed 3D the of view 9–Another Figure 12CF material. Nylon FDM in printed 3D parts 8–Aerodynamic Figure Solution Brief 7 assign custom infill settings to specific areas of a part to optimize its build. its optimize to part ofa areas specific to settings infill custom assign to software Print GrabCAD in features FDM Advanced the of 11Figure –Ascreenshot performance andlowercost. and pushproducts tomarketfaster, withbetter methods, manufacturers canfollowMcLaren’s example as astrongtootherfabrication butlightweightalternative requirements thatneedtobemet.UsingFDMNylon 12CF limit, mostbusinesseshavedeadlinesanddemanding Whether it’s Sundayracedayorsomeothertime operators. help withcommunicationbetweenengineersandmachine allows userstoleavemanufacturingnotesonthepart GrabCAD PrintworkswithallcommonCADformatsand shows theinfillsettingsbeingadjustedinsoftware. portions oftheCADmodelforpartslikethis.Figure 11 extremely easytoassigndifferent toolpathstoindividual settings asneededtooptimizethepart,andmakesit software istheabilitytoadjustprint and GrabCAD Print shaker tabletolookfordefects.Thevalueof3Dprinting 3D printedwithFDMtechnologyready togothe shows apartiallycompletedcompositebrakewing just liketheirtraditionalcounterparts.Figure 10 go through McLaren’s rigorous qualitytests Additively produced composite partsmust Production Parts 3D Printed

Figure 10 – A 3D printed brake wing ready to undergo quality testing. quality undergo to ready wing brake 10 printed –A3D Figure Solution Brief 8 parts notonlyresulted ina60%fasterleadtimebut were also86%cheaper. features helpchannelairintothebrakingsystemand managetheflowenteringfront ofthecar. These That wasthecaseindevelopmentoffront brakeductsshowninFigure 12.Theseaerodynamic manufacturing process, amajorsource ofcosthasalsobeenremoved. some circumstances, it’s alsocheaper. Thereason liesinthefactthatbyeliminatingtoolingfrom the printing productiontheeconomicscompletely onitshead.It’s partsturns notonlyfastertoprint,butin returns tobeingearlyonaproject ifyoucan’t meetyourclient’s budget. McLaren F1hasfound that3D For manymanufacturingbusinesses,timeisimportant butultimatelycostiskingandthere are diminishing The BottomLine:Cost Production Parts 3D Printed 1car. Formula McLaren the of front the on features aerodynamic 12 –The Figure

Solution Brief 9 custom solutionsare required. producers, theaerospace industry, andanywhere automotive companies,manufacturingequipment required. Thisisagreat solutionforinnovative - sometimeswithinthesamedaywithnotooling intricate parts,AMenablesquickturnaround times could bethebestviableoption.Forlow-volume, AM andcreating partsdifficult tomakeotherwise through atightorcomplexarea, designingfor printed assembly. Whenrouting necessary airflow compartment attheidealtemperature viaa Another exampleinvolveskeepingthepassenger manufactured parts. the outsideenvironment bymeansofadditively cooling mechanicalcomponentsexposedto be modelledafterMcLaren’s printedductinclude Applications intheautomotiveindustrythatcould time andexpenseby3Dprintingthem. composite assemblyormetalfabrication,theysave to traditionalmanufacturingprocesses suchas their ductdesignperyear. Insteadofresorting McLaren produces onlytwoorthree sectionsof components from overheatinganddamage. This keepstheengineanditsairflow-dependent appropriately intotheoriginaldesignofcar. an electricfaninlet,McLaren printspartsthatmate prior tothestartofrace.To neatlyinterfacewith garage, betweenpracticeruns,qualifyinglaps,or stationary duringvariousintervalssuchasinthe 3D printedparts.They’re used whenthecaris McLaren coolstherear oftheenginebayusing when thecarisparked.Figure 13showshow automobiles, theyneedforced supplementalairflow large radiatorfanslikethosefoundinproduction still needairflow. Sincethevehiclesdonot have But whenthecarisn’t moving, certaincomponents components. to disturbcompetitors’cars,andcoolheat-critical downforce tokeepthecar stable,create dirtyair They enhanceperformancebyproviding additional F1 carsare notedfortheiraerodynamic features. Custom EngineBayCoolingDuct Figure 14 - The cooling duct on McLaren’s F1 race car in the pit row. pit the in car F1 race McLaren’s on duct 14 cooling -The Figure duct. printed a3D with bay engine the of part rear the 13 -Cooling Figure 10 Solution Brief to allowthetire changerstodotheirjobsmoothlyand withoutstrain. race entirely. It’s acritical pieceofpithardware andneedstobeprotected. Butitalsohastobeergonomic seconds. InF1racing,afew extramillisecondsduringapitstopcanmeandropping positionorlosingthe you canblink.Thistoolneedstofunctionefficiently and repeatedly sincetheaveragepitstopisabout2.5 One suchtoolisthewheelgun,whichremoves andinstallsthecar’s tires duringapitstopfasterthan Every profession hasitsspecializedtoolsthathaveequallypricetags.F1racingisno different. Custom Tools –AdditiveisaGreat Team Player Tooling Design & Development Director McLaren Oatley Neil design, before we commit to long term production composite components.” afinal at to arrive options tooling multiple in investing without quickly very solution ergonomic performing best the on in hone to details design iterate we can Meaning tooling. without and quickly part complex avery to us build allows this “Essentially 11 Solution Brief the desired compositeduct. sacrificial molddissolves,leaving behind immersed inadissolutiontank where the Once thecompositematerial iscured it’s mold isthenwrappedincarbon fiber. ST-130 sacrificialtooling material.The in Figure 17,andis3Dprintedusing mold oftheduct’s shape,shown internal make theparts.Thesolublecore formsa In thissituation,McLaren usessacrificialcores to the partscan’t evenbemadewithtraditionaltooling. both methodshavedrawbacksandinsomecases, usually requires complex toolsorclamshellmolds.But are compositetubesandducts.Fabricatingtheseparts Some ofthemore difficult partstomakeonF1cars Complex Tooling MadeSimpleWithSolubleCores that limitstheapplicationisimagination. equipment. McLaren theonlything haslearned fixtures suchasconformalsoftjawsandtesting application isnotlimitedtotoolcovers,butalso around theworldalready know, thistypeof As McLaren andcountlessothermanufacturers customization forergonomiccomfortandsafety. weighting foreasierusabilityandeasy objectives: protection forequipment, light- is agoodfitfortooling,satisfyingmultiple It’s aperfectexampleofhowFDMtechnology maximum comfortandusability. freedom letsMcLaren configure theshellfor pit area. Alongwiththat,3D printing’s design from beingdamagedasit’s movedaround the prevents theexpensiveelectro-pneumatic gun and 16.TheruggedFDMthermoplasticmaterial custom wheelgunshell,showninFigures 15 To achievebothgoals,McLaren 3Dprinteda printed protective cover. protective printed 3D its with gun wheel the using member 15 crew –Apit Figure duct shown in Figure 18. Figure in shown duct composite the form to apattern as used core) (soluble tool 17 –Asacrificial Figure separately. wheel gun shroud shown printed 3D 16 –The Figure 12 Solution Brief Figure 18 – The final composite duct with the soluble ST-130 material dissolved away. dissolved ST-130 soluble material the with duct composite final 18 –The Figure manner, 3Dprintedsolublecores are amongthemostefficient solutions. Racing, whenthere’s aneedtomakehollow, complexcompositepartsinatimelyandcost-effective aerospace manufacturing, automotive,customsportinggoodsandmedicaldeviceresearch. LikeMcLaren This process isalsoused in manyotherindustries,includingfactoryautomation,bicycleproduction, to thetimeandcostofmakingtraditionaltooling. a fastandsimplewaytomakesmallbatchesofcustom,high-performancepartsisgreat alternative The resulting partispictured inFigure 18afterthesolublecore hasbeendissolvedaway. Thisapplicationis Tooling 13 Solution Brief specifications subject tochange Racing_0521a without notice. SB_FDM_McLaren respective their of property the are owners, and Stratasys trademarks assumes other no responsibility All with Inc. regard to the selection, Stratasys, of performance, or use of these J850, non-Stratasys trademarks 12CF PolyJet, are products. Inc. Nylon Product FDM and Stratasys of Print GrabCAD trademarks VeroUltraClear, registered are FDM and logo Signet Stratasys the Stratasys, reserved. rights All © 2021 Stratasys. ISO 9001:2015Certified stratasys.com +1 952937-0070(Fax) +1 952937-3000(Intl) +1 8008016491(USToll Free) Eden Prairie,MN55344 7665 Commerce Way, Stratasys Headquarters contact aStratasysrepresentative today. To jointheranksofMcLaren andcountlessothercompaniesthatbenefitfrom 3Dprintingtechnology, same advantages. McLaren exemplifieshow3Dprintingbenefitsonecompany. Butyourbusinesscouldjustaseasily reapthe improve workersafetyandcomfort? for lesscostthanconventionaltoolsimpactyourproduction schedule?Would lighter, more ergonomictools If you’re amanufacturer, howwouldthecapability tomakeneworreplacement jigsandfixtures fasterand achieve betterdesignsgetyoutomarketmore quickly? If you’re inthebusinessofbringingnewproducts tomarket,wouldtheabilityprototype fasterand business inanyindustrycanleveragetoimprove processes andultimately, thebottomline. some specializedtechnologylimitedtoonlyFormulaOneracingteams.Rather, it’s atoolthatvirtuallyany Simply put,McLaren maximizes3Dprinting’s capabilitiestogetbetterresults andgofaster. Butit’s not Beyond the

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