Additive Manufacturing in Formula 1®
Dipl. Ing. Christoph Hansen «Head of Additive Manufacturing»
The Sauber Group› History
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The Sauber Group
More than 45 years of history in motorsports
1970 1982 1988 1989
Founding of thePP 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
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The Sauber Group
More than 45 years of history in motorsports
2003 2006 20101993
Formula 1 entry Construction of the own wind tunnel.
BMW takes over the Sauber Team
Peter Sauber bought back the Sauber F1 Team
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The Sauber Group
More than 45 years of history in motorpsorts
20182016
Longbow Finance buys the Team.
Alfa Romeo becomes the teams title Sponsor.
The story continues… Don’t miss the Alfa Romeo Sauber F1 Team’s first race in Melbourne on March 25, 2018
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› 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
Additive Manufacturing at Sauber
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Additive Manufacturing at Sauber
History
› 1995 - 2007 The AM parts were purchased from external suppliers.
› 2007 Set up of the own production
Machines: 5 SLA1 SLS
› 2008 - 2018 Due to the rising demand of AM parts, the machinepark had to be extended constantly.
Machines: 6 SLA6 SLS
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Additive Manufacturing at Sauber
History
› 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 aregoing to be extendedwith an additional coreand a storage module
› 06/2017 The partnership wit AI was officiallyannounced
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ParameterHiPAC
(SLS) 1)
Bluestone
(SLA) 2)
HPC
(SLA) 2)
Xtreme
(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 8300 - 9800 MPa 9000-9700MPa 1520 - 2070MPa
Flexural strength 132MPa 124 - 154 MPa 137-157 MPa 52 - 71 MPa
E module tensile force 8304MPa 7600 - 11700MPa 8700-1200MPa 1790 - 1980 MPa
Tensile strength 85MPa 66 - 68 MPa 66-89MPa 38 - 44MPa
Crack expansion 2.7% 1.4 - 2.4 % 0.8-1.9% 14-22%
Melting point 172-176 °C
Heat resistance ca. 170°C 54°C
Glass transition temp. 71 - 83 °C 62-73°C
2) Accura® Bluestone / HPC / Xtreme - 3DSystems product1) HiPAC® developed by Sauber Engineering AG
Additive Manufacturing at Sauber
Material Selection Plastic AM
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ParameterAlSi10Mg
(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
Additive Manufacturing at Sauber
Material Selection Metal AM
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Additive Manufacturing at Sauber
AM on the F1® car
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Additive Manufacturing at Sauber FrontwingBenzing (Test)
HiPAC/Metalcoated/
Painted
Brake duct scoopsHiPAC
Roll HoopHigh Strength Aluminium
AM on the F1® car
Cooling Ductsfor Elecrtics
HiPAC
Upright CoversAluminium
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Additive Manufacturing at Sauber
AM on the F1® car
Exhaust andTurpo Pipes
Inconel / Titanium
Intercooler Pipe/Radiator Interface
Aluminium
Garage equipmentHiPAC/Aluminium
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Additive Manufacturing at Sauber
AM in the F1® car production
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Additive Manufacturing at Sauber
AM in the F1® car production
› Mold Production › Laminating cores › Trim and Bonding jigs
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Additive Manufacturing at Sauber
AM in Aerodynamics
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Additive Manufacturing at Sauber
AM in Aerodynamics
BodyworkSLA/SLS
Front and rear Wing parts
Aluminium, SLA
Wishbone coversSLA
Coolers and Internals(Pressure taps integrated)
SLA
Floor(Pressure Taps integrated)
SLA
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Additive Manufacturing at Sauber
Third Party Business
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Additive Manufacturing at Sauber
Third Party Business
Fields
› Prototyping› Serial Production› Spare part Production
Main Applications
› Automotive Industrie› Industrial Printing Industry› Space and Aviation
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Additive Manufacturing at Sauber
The Future of AM in the Sauber Team
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Additive Manufacturing at Sauber
The Future of AM in the Sauber Group
› Setup engineering capabilities
› Setup in depth technology know-how
› Understand and control processes in depth
› Setup in depth material know-how
› Colaborations with universities
Become Center of Excelence in Additive Manufacturing
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Thank you very much !Contact Information
Christoph Hansen, Head of Additive ManufacturingSauber Engineering AG, Wildbachstrasse 9, 8340 Hinwil, Switzerland
Phone: +41 44 937 95 48Mobile: +41 79 774 50 83