Additive ManufacturingBuild on our experience

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What is Additive Manufacturing?

Additive manufacturing or rapid prototyping is almost magical. In conventional machining processes, material is removed from a solid material such as wood or metal in order to reach the desired shape (for example, by milling or eroding machines).

Additive processes build up the desired shapes in layers by means of a "3D printer". 3D Metal Printing and Selective Laser Sintering (SLS) use a powder as the starting material and a laser "sinters" the object layer by layer. Stereolithography (SLA), is based on a laser hardening a photosensitive liquid resin in layers to make the desired part arise.

Additive rapid prototyping processes open up unimagined opportunities, right down to the fast and cost-effective production of small-series for even the most complex of components.

Advantages

In motorsport, additive manufactured parts are even used for racing on the track. Our experts are looking forward to assist you with their advice.

Additive manufacturing offers the following advantages compared to conventional production processes:

▪ Unlimited shaping (undercuts, cavities, complex geometries)▪ Lightweight construction▪ Tangible, fully functional parts within the shortest time▪ Excellent cost vs benefit ratio: no tooling costs▪ Small series: individual products within a series without additional costs▪ Time-to-market and just-in-time production: manufacture parts as required▪ Reduced capital tied up in stock: parts can be manufactured quickly

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Machine park and building space

With a total of 12 large-volume production machines, our machine park in Hinwil, Switzerland offers an outstanding capacity.

By so-called "splitting" and subsequent bonding, we are able to manufacture parts that are larger than the building space (or installation space) of the individual machines shown below 1).

Nr. of machines Type of machine Building space 1)

SLS (Selective Laser Sintering) 500 x 500 x 750 mm

SLS (Selective Laser Sintering) 500 x 500 x 440 mm

SLA (Stereolithographie) 650 x 750 x 480 mm

3D Metal Printing 420 x 420 x 400 mm

1) Maximum size of parts without splitting; bigger parts are possible by splitting & bonding.

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3D Metal PrintingThe MetalFAB1 system completely melts thin layers of metal alloy powders on a large build platform with up to four lasers.

The end products are fully functional metal parts with superior material properties better than casting and higher mechanical strength than SLS and SLA.

The metal additive manufacturing technology offers almost full design freedom to include lattice and honeycomb structures, voids and integrated channels.

Advantages of 3D Metal Printing:

▪ Functional end-use parts▪ High mechanical strength and superior material properties▪ Parts can be machined, spark-eroded, welded, micro shot-peened, polished and coated, if required▪ Perfectly suited for light-weight applications

Thanks to our partnership with Additive Industries, we are able to apply the latest industrial metal additive manufacturing technology.

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Selective Laser Sintering (SLS)Like 3D Metal Printing, SLS is a powder-based manufacturing process. The main difference is that SLS only partly melts (sinters) the powder particles.

One of the advantages of SLS manufacturing processes is that they do not require support structures, as the object being printed is constantly surrounded by unprocessed powder.

Advantages of SLS:

▪ High mechanical and thermal stress resistance of the parts▪ Parts can be used immediately▪ Simple mechanical finishing as no supporting structure needs to be removed▪ Quicker than 3D Metal Printing or SLA▪ Stronger parts than SLA, more suited for functional engineering parts

Stereolithography (SLA)SLA is based on a photosensitive resin (photopolymer), which is hardened by a laser in thin layers.

The procedure is done in a bath, which is filled with the base monomers of the photosensitive resin.

This method allows for higher resolutions and, thus, higher accuracy than other methods.

Advantages of SLA:

▪ Exceedingly high accuracy▪ Offers extremely high resolution▪ Advantageous when producing parts with cavitites▪ Smooth surface finish

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Our materialsWe use the following materials of which the most important properties are:

1) HiPAC is a proprietary material developed by the Sauber F1 Team2) Accura® Bluestone by 3DSystems3) Accura® Xtreme by 3DSystems4) AlSi10Mg is an aluminium alloy by Additive Industries

Parameter HiPAC 1)

(SLS)Bluestone 2)

(SLA)Xtreme 3)

(SLA)AlSi10Mg 4)

(3D Metal Printing)

Type of material Carbon-reinforced polyamide 12

Nano composite epoxy resin

Epoxy resin Aluminium alloy

Density solid – 1,78 g/cm3 1,19 g/cm3 2,67 g/cm3

E module bending 7327 MPa 8300 - 9800 MPa 1520 - 2070 MPa 65000 MPa

Flexural strength 132 MPa 124 - 154 MPa 52 - 71 MPa –

E module tensile force 8304 MPa 7600 - 11700 MPa 1790 - 1980 MPa –

Tensile strength 85 MPa 66 - 68 MPa 38 - 44 MPa 400 MPa

Crack expansion 2,7 % 1,4 - 2,4 % 14 - 22 % 3 %

Melting point 172 - 176 °C – – –

Heat resistance ca. 170 °C – 54 °C –

Glas transition temp. – 71 - 83 °C – –

Characteristics Excellent chemical resistance, high dimensional stabi-lity, very low water absorption

High stiffness, heat and abrasion resistant, excellent chemical resistance

Tough and durable, resists breakage, handles challen-ging functional assemblies

Offers good strength and hardness, high dy-namic and thermal properties, resists high loads, ideal for parts with thin walls and complex geometry

Applications Race car parts, wind-tunnel test models, fixtures, jigs and tools, auto-motive prototyping, pre and small series

Wind-tunnel test models, fixtures, jigs and tools, lighting compo-nents, “under-the-hood“ automotive parts and electrical components

General purpose, snap fits, assem-blies and deman-ding applications, ideal for master patterns for vacuum casting

Functional prototypes, series-production parts, motorsports, automotive/ series-production vehicles, aero-space interior

HiPAC HiPAC is a proprietary development for laser sintering by our company. It is based on a carbon-reinforced polyamide 12.

PA 12 stands out due to its extremely low water absorption compared to other polyamides. It is therefore characterised by a particularly high dimensional stability and the minimal influence of moisture on its mechanical properties.

Due to its unique properties, we use HiPAC in Formula 1 for various components of our racecars. For example, HiPAC- based brake cooling ducts are driven directly on the race track.

HiPAC = High-Performance PolyAmide Carbon-reinforced is resistant to:

▪ Petrol▪ Oils and fats▪ Esters▪ Alcohols▪ Ketones▪ Ether▪ Hydrochlorofluorocarbons▪ Alkalis▪ Diluted acids

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Customer-oriented finishingOur parts are typically delivered in standard sandblasted raw finish. In addition, we offer the following individual surface processing:

Polished

Lacquered (matt, glossy, 1 or 2 K lacquer according to individual colour code)

Plastered / laminated with foil

Metal-coated

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Our services in a nutshell

Besides the actual production of additive manufacturing parts we support you with the following additional service options:

▪ Consulting (processes, concept, design)▪ Construction / CAD▪ Quality assurance, right up to 3D scans▪ Assembly and complete models▪ Coatings▪ Express deliveries

What can we do for you? Rely on decades of racing experience and expertise in additive manufacturing and problem solving! Our specialists are ready to advise you in all matters relating to our offers. Please contact us.

+41 44 937 96 70 – Your Additive Manufacturing Hotline

rp.info@sauber-motorsport.com

Sauber Aerodynamik AGWildbachstrasse 98340 HinwilSwitzerland

sauberf1team.com