October 27, 2021

Automotive Mogul

Automatic Road Vehicle

Sauber’s F1 technology used in production of additively manufactured classic car parts

The team at Sauber had been recently challenged to build a substitute gearbox housing for a 1950s Ferrari 340 America Barchetta (Courtesy Sauber Engineering)

Sauber Engineering AG, portion of the Sauber Team, is hunting to enter the basic vehicle ingredient supply business with a support able of offering reverse engineering and Additive Manufacturing of crucial factors.

With an automotive history dating back about forty years, Sauber will apply its knowledge and know-how applied in Formula 1 to manufacture sections for classic cars, exactly where an aftermarket offer chain is confined, or no for a longer time exists.

Conversing to Metal AM journal, Christoph Hansen, Director Technological innovation & Innovation at Sauber Engineering, was eager to clarify the reasoning behind the venture. “At Sauber, we have a wealth of expertise and understanding of automotive engineering. Mix this with our practical experience in Additive Production for large-overall performance F1 components, and we can give the historic auto sector one thing exceptional – a one particular-end-store to change broken or weakened parts that would if not mean the conclusion for that car or truck.”

Sauber has both equally polymer and metallic AM machines at its facility in Zürich, Switzerland, and has been making use of them for a quantity of yrs to produce the two prototype and operating factors. “We can now give the vintage car or truck owner a assortment of solutions, from straightforward plastic covers, up to total gearbox housings or engine parts,” extra Hansen.

The rear axle gearbox was terribly damaged and not possible to mend (Courtesy Sauber Engineering)

Sauber Engineering AG, part of the Sauber Team, is on the lookout to enter the basic car or truck element provide business enterprise with a company able of giving reverse engineering and Additive Producing of crucial elements.

With an automotive history dating again in excess of forty decades, Sauber will utilize its abilities and technological know-how applied in Formulation 1 to manufacture pieces for classic motor vehicles, exactly where an aftermarket offer chain is limited, or no lengthier exists.

Chatting to Steel AM journal, Christoph Hansen, Director Know-how & Innovation at Sauber Engineering, was keen to explain the reasoning driving the challenge. “At Sauber, we have a prosperity of understanding and knowing of automotive engineering. Mix this with our expertise in Additive Producing for substantial-general performance F1 elements, and we can supply the historic automobile sector something unique – a a person-stop-shop to substitute broken or broken elements that would otherwise imply the close for that car or truck.”

Sauber has equally polymer and metal AM equipment at its facility in Zürich, Switzerland, and has been making use of them for a range of many years to create each prototype and performing factors. “We can now provide the traditional car or truck proprietor a variety of options, from easy plastic covers, up to full gearbox housings or motor sections,” additional Hansen.

The crew reverse engineered casing was optimised for the AM approach (Courtesy Sauber Engineering)
The re-made gearbox casing was additively made at Sauber Engineering’s Zürich facility (Courtesy Sauber Engineering)

This is wherever the wealth of automotive knowledge at Sauber is vital. “We know what tolerances a gearbox desires to be crafted to, we know what supplies are best to use. We can then implement our working experience to design and style the component, generating it not only perform, but earning it carry out much better than the primary,” ongoing Herzog.

In some circumstances, of class, a ingredient can be fixed, but this was not possible with the Ferrari gearbox. “The gearbox was terribly harmed and split throughout the casing. Our only possibility was to reverse engineer the housing, which associated a total 3D scan of the composition and then optimisation of the CAD file to create a design that could be additively produced,” included Hansen.

The gearbox housing was developed in-residence making use of a MetalFAB1 system from Additive Industries. The MetalFAB1 is a Laser Beam Powder Mattress Fusion (PBF-LB) machine able of manufacturing components from a broad range of metals, which include maraging or device metal, aluminium, Scalmalloy, titanium and nickel alloys.

The additively made gearbox casing was machined to meet up with the required tolerances (Courtesy Sauber Engineering)

“The Ferrari gearbox was crafted from aluminium (AlSi10Mg) and took around 5 days of printing making use of our very own in-home created higher-pace parameter set. It then underwent a quantity of put up-processing functions and inspections. Many thanks to our design optimisation, the closing part was actually lighter and additional reliable than the first casing,” mentioned Hansen.

“Our aim with Sauber’s new historic automobile parts business is to keep these aged classics alive, on the highway and staying made use of for what they had been built for. By working with today’s engineering we can realize this, making sure these essential and a great deal cherished historic cars and trucks do not vanish,” concluded Herzog.

The crew at Sauber can be contacted by means of e mail: [email protected]