July 29, 2021

Automotive Mogul

Automatic Road Vehicle

Sauber draws on Formula 1 expertise to 3D print spare parts for vintage cars

A Ferrari 340 America Barchetta.

Sauber Engineering AG, a division of the historic motorsport staff Sauber Team, has instructed Metal AM that it intends to establish a 3D printing business enterprise for manufacturing on-need vintage automobile spare sections. 

Harnessing the understanding gained from its 28 12 months-stint as a Method 1 group, Sauber Engineering is now trying to find to established up a company, which provides to reverse engineer and print spares for heritage cars. The new venture is designed to tackle the wants of classic car lovers, whose prized belongings need mend, but can no longer count on the aftermarket guidance of indigenous suppliers. 

“At Sauber, we have a wealth of knowledge and comprehending of automotive engineering,” stated Christoph Hansen, Director Engineering & Innovation at Sauber Engineering. “Blend this with our practical experience in AM for significant-general performance F1 parts, and we can give the historic car sector anything exclusive – a one-halt-store to exchange broken or destroyed parts that would or else mean the conclusion for that car or truck.”

“We can now provide the classic auto owner a assortment of choices, from easy plastic handles up to comprehensive gearbox housings or engine areas.”

A Ferrari 340 America Barchetta.
Sauber has presently managed to 3D print a substitute component for a Ferrari 340 America Barchetta. Impression via RM Sotheby’s.

Sauber’s motorsport heritage 

Due to the fact it was started in 1970, Sauber has developed up a storied background of motorsport good results, in which it has introduced the Silver Arrows name back to the race keep track of, and won the 24 hours of Le Mans. Sauber’s F1 staff has also taken component in the activity continuously considering that 1993, bringing household 865 factors in the method, and it continues to race under the Alfa Romeo Racing ORLEN banner to this working day. 

In excess of the last three many years, Sauber’s partnership with Alfa Romeo has noticed it steadily integrate additive created elements into its race automobiles. In 2020, the team’s ‘C39’ version highlighted 143 3D printed elements, but this has now been ramped-up to 304 for this season’s ‘C41,’ in a system that is approximated to have minimized their price tag by 90%. 

The elements themselves were crafted employing Additive Industries’ machines at Sauber’s Metal 3D Printing Competence Heart, which now residences 13 methods that generate 22,000 parts each calendar year. Leveraging its developing AM capabilities, which includes a few new AM Options S1 post-processing systems, Sauber is now seeking to utilize its F1 knowledge elsewhere, in the restoration of timeless automotive classics. 

Christoph Hansen, Director of Technology & Innovation of Sauber Engineering, with Stephan Rösler, President & CEO of the Rösler Oberflächentechnik GmbH. Photo via Rösler Group.
Sauber has partnered with AM Answers to bolster the publish-processing of its 3D printed race car parts. Image by using the Rösler Group.

Renovating an automotive classic 

In advance of the launch of its new services, which will offer shoppers every little thing from 3D printed covers to engine sections, Sauber has previously been challenged with creating a gearbox housing for a basic Ferrari 340 America Barchetta. Equipped as standard to the car’s rear axle, the damaged ingredient could no for a longer time be changed because of to its sheer rarity, when its age meant that its schematics couldn’t be sourced either. 

“The gearbox was poorly weakened and split across the casing,” stated Hansen. “Our only choice was to reverse engineer the housing, which included a complete 3D scan of the framework and then optimization of the CAD file to create a style that could be additively created.” 

Through the reverse engineering process, Sauber Engineering’s group leveraged their prosperity of automotive experience to construct a re-made gearbox, which not only highlighted the in-constructed tolerances essential for stop-use operation, but was eventually able of outperforming the original. 

Developed making use of an Additive Industries MetalFAB1 3D printer at Sauber Engineering’s Zürich facility, the ensuing aluminium component took around five days to create. When printed, the part was subjected to submit-processing and stringent screening, in the course of which it proved to be both equally lighter and far more long lasting than its authentic Ferrari-created predecessor. 

“Our purpose with Sauber’s new historic automobile pieces business enterprise is to keep these outdated classics alive, on the street and remaining employed for what they were being developed for,” concluded Jonathan Herzog, Sauber’s Head of Undertaking Administration & Revenue. “By utilizing today’s know-how we can obtain this, making certain these significant and much cherished historic cars and trucks do not vanish.”

3D printing spares and repairs 

The convergence of reverse engineering procedures, digitized inventories and 3D printing are significantly enabling the redesign and producing of uncommon or discontinued elements. Earlier in 2021, SOLIZE introduced that it was working with HP as aspect of a similar venture, to additive manufacture spares for some of Nissan’s NISMO line of heritage sports activities cars and trucks.

In the earlier, British restoration workforce, Redesign Sport has also used 3D scanning and CAD modelling to reverse engineer a basic Ferrari. The business used a Creaform system to scan elements of a vintage 1952 Ferrari 225 in advance of outsourcing their generation, and fitting them to the vehicle all set for its presentation at the Goodwood Revival pageant. 

In other places, equivalent reverse engineering techniques have been deployed by the U.S. Military Aviation and Missile Command (AMCOM) to totally 3D model a UH-60L Black Hawk helicopter. By making a electronic twin of the transport plane, the U.S. Military aims to set up a catalog of digital elements, which in turn, could be utilised as a implies of 3D printing some of its much more complicated-to-source factors. 

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Highlighted graphic exhibits a Ferrari 340 The usa Barchetta. Image by means of RM Sotheby’s.