Additive Manufacturing in Formula 1. Dipl. Ing. Christoph Hansen «Head of Additive Manufacturing»

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Everett Holland
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1 Additive Manufacturing in Formula 1 Dipl. Ing. Christoph Hansen «Head of Additive Manufacturing»

2 The Sauber Group History

3 The Sauber Group More than 45 years of history in motorsports Founding of the PP Sauber AG First assignment to build a Le Mans Prototype Sauber becomes the official Mercedes Benz factory team. Sportscar world championship title and double victory at the 24h of Le Mans Page 3

4 The Sauber Group More than 45 years of history in motorsports Formula 1 entry Construction of the own wind tunnel. BMW takes over the Sauber Team Peter Sauber bought back the Sauber F1 Team Page 4

F1 Team s first race in Melbourne on March 25, 2018 Longbow

5 The Sauber Group More than 45 years of history in motorpsorts The story continues Don t miss the Alfa Romeo Sauber F1 Team s first race in Melbourne on March 25, 2018 Longbow Finance buys the Team. Alfa Romeo becomes the teams title Sponsor. Page 5

6 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

History 1995-2007 The AM parts were purchased from external suppliers.

7 History The AM parts were purchased from external suppliers Set up of the own production Machines: 5 SLA 1 SLS Due to the rising demand of AM parts, the machine park had to be extended constantly. Machines: 6 SLA 6 SLS Page 7

History 06/2017 The partnership wit AI was

8 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

9 Material Selection Plastic AM Parameter HiPAC Bluestone HPC Xtreme (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 MPa MPa MPa Flexural strength 132MPa MPa MPa MPa E module tensile force 8304MPa MPa MPa MPa Tensile strength 85MPa MPa 66-89MPa 38-44MPa Crack expansion 2.7% % % 14-22% Melting point C Heat resistance ca. 170 C 54 C Glass transition temp C C 1) HiPAC developed by Sauber Engineering AG 2) Accura Bluestone / HPC / Xtreme - 3DSystems product Page 9

10 Material Selection Metal AM Parameter AlSi10Mg (DMLS) Titanium Ti64 (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

11 AM on the F1 car Page 11

12 AM on the F1 car Cooling Ducts for Elecrtics HiPAC Roll Hoop High Strength Aluminium Frontwing Benzing (Test) HiPAC/ Metalcoated/ Painted Brake duct scoops HiPAC Upright Covers Aluminium Page 12

13 AM on the F1 car Garage equipment HiPAC/Aluminium Exhaust and Turpo Pipes Inconel / Titanium Intercooler Pipe/ Radiator Interface Aluminium Page 13

14 AM in the F1 car production Page 14

15 AM in the F1 car production Mold Production Laminating cores Trim and Bonding jigs Page 15

16 AM in Aerodynamics Page 16

17 AM in Aerodynamics Bodywork SLA/SLS Wishbone covers SLA Coolers and Internals (Pressure taps integrated) SLA Front and rear Wing parts Aluminium, SLA Floor (Pressure Taps integrated) SLA Page 17

18 Third Party Business Page 18

19 Third Party Business Fields Prototyping Serial Production Spare part Production Main Applications Automotive Industrie Industrial Printing Industry Space and Aviation Page 19

20 The Future of AM in the Sauber Team Page 20

21 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

22 Thank you very much! Contact Information Christoph Hansen, Head of Additive Manufacturing Sauber Engineering AG, Wildbachstrasse 9, 8340 Hinwil, Switzerland Phone: Mobile: Page 22

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Fusion Equipment & Tools Electrofusion Processor Scraper Tools Rerounding Tools Socket Fusion Kit 71 I Fuse 105 Electrofusion Processor The IntegriFuse I Fuse 105 Electrofusion Processor is the next generation