The auto racing world moves fast, too fast to ignore the quick and effective CAD-to-part manufacturing offered by 3D printing technology. DeltaWing is one of the leaders in sustainable racing cars, offering half the weight, aerodynamic drag, and horsepower of its competition. Between 2012 to 2013, Delta Wing racing cars went through a huge transformation. An entirely new crew, operating team, tire partner, and engine made for an exciting couple of years. And the evolution of Delta Wing’s engine was essential to the team’s success on the track. And, because there is such a quick turnaround time between races, DeltaWing’s engine must perform reliably under severe time constraints.
In order to strike the perfect balance between innovation, technology, and efficiency, DeltaWing design engineer Christian “Skitter” Yaeger, turned to CRP USA to help him produce and design a new engine. This collaboration yielded results as quickly as a turn around the track, going from nothing but a Mazda head to a new engine in 81 days, to racing a Sebring in 105 days. How did they do it so fast? They used a 3D printed intake manifold.
“We could not have made this motor happen if we couldn’t produce parts directly from CAD files. The biggest benefit is being able to print exactly what you need. We have eight odd-shaped ports in the head, and CRP USA was able to match them perfectly, with a knife edge in between,” said Yaeger.
The DeltaWing car that launched in 2013, complete with a 3D printed manifold pushed the boundaries of both what DeltaWing had done before and what to expect in the racing industry in the future. The intake manifold uses a combination of 3D printing technology and CRP’s high-performance Windform SP material for its construction, and successfully operates under boost used in race conditions. This new component offers a marriage between 3D printing technology and innovative materials technology that is perfect for racing conditions.
Yaeger continues, “Over the past two years, the 3D Printed manifolds have covered over 12,000 testing and racing miles, along with 6 hours per unit running on the dyno.”
Windform and 3D printing technology
Windform SP is a composite polyamide-based, carbon-filled material that was introduced to DeltaWing by CRP USA . It is not only shock resistant, but it is also highly resistant to deformations, vibrations, liquids, and moisture. DeltaWing had previously used the material to make transmission seal covers; integrated, pressurized oil feed passages; and electronics enclosures. So, when DeltaWing engineers needed a high performance material tough enough to handle the tension and heat of an engine intake manifold, CRP USA submitted Windform as a material for consideration.
“The packaging constraints required by the location of the engine within the chassis requires some creative design. The runner lengths attach at the base of the plenum and form a complex structure that would be extremely difficult to build without using additive manufacturing. Windform SP’s toughness and heat deflection temperature allow the part to be built and then raced in the endurance series. The engine is run under boost, so it sees pressure variation in addition to the vibration, shock, and temperatures changes associated with racing,” said Stewart Davis, Director of Operations at CRP USA.
Davis adds that, “The work done by Skitter and the DeltaWing/Élan Motorsports team is a great example of the application of Windform for a complex problem, and utilizing Additive Manufacturing to push the boundaries in racing.”
Windform and 3D printing technology, under the guidance of DeltaWing/Elan Motosports and CRP USA, has turned out to be a winning combination.
