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Stratasys’ 3D Printing Increases Power & Efficiency of HTW Racecar

If you thought resins and Digital ABS materials were not tough enough to compete with genuine plastics in high performance situations, think again: Stratasys worked with HTW Motorsports, a student derived project from the University of Applied Sciences in Berlin, to build the airbox for their BRC2014 Formula type race car. Not only was Stratasys’ Digital ABS used for producing the final component, but, through the company’s PolyJet technology, the manufacturing process was improved both in terms of cost and workflow efficiencies.

stratasys HTW airbox

That 3D printing is used for making race car parts is not news. Both Formula One and NASCAR are among professional 3D printing’s first and largest adopter, both in prototyping and in the production of components for final use during the races. However, this case study proves that the advantages of 3D printing as a manufacturing process are now so significant that they can be passed onto projects with significantly lower budgets, and that PolyJet materials are tough enough to be used in final components for race cars.

“As a university project, having access to Stratasys’ advanced 3D printing technology offers us a massive boost,” said Patrick Harder, team engineer at HTW Motorsports, “It enables us to develop the required parts much faster and incredibly more cost-effectively than we would otherwise be able to.” Every year the team develops a new model to compete with and is constantly studying new ways to make the vehicle lighter and the production phase more efficient.

“[3D printing] has delivered proven, quantifiable benefits on the BRC14’s airbox system, with a comparative increase in horsepower of around 10% versus the system we used two years before. We also enjoyed an increase in torque of almost 12% over the same timeframe,” said Harder.

HTW team

The guys from the HTW team explained to me that a well-designed airbox will draw air more efficiently and effectively into the engine and, thus, improve performance. 3D printing is used both to create a functional prototype and a part of the final race vehicle as Stratasys’ Digital ABS can guarantee sufficiently high temperature resistance and fuel resistance, which are vital prerequisites for the airbox. “This, and its high strength-to-weight ratio, make it the best material for the airbox’s plenum chamber which requires a combination of toughness, unique geometry and high surface finish,” Harder said.

The HTW team is already working on the new 2015 version which will be presented in June and compete in the upcoming season. The upgraded model will integrate more 3D printed components in order to reach the goal of reducing the car’s weight by 45Kg. “We are planning on introducing a fully 3D printed steering wheel and fuel tank, as well as a slightly smaller 3D printed airbox,” Harder explained. “We’ll also be constructing a number of boxes that house the many micro-controllers on the car and expect 3D printing to deliver almost 80% weight reduction compared to using standard options from electronic suppliers.”

At this rate, and with Stratasys’ support, the Formula-style race car’s performance and the young engineering students’ experience are likely to increase exponentially. Current top speed, they told me, is set at about 130 Km/h. When you are sitting a few centimeters from the road, you feel every bit of speed. Will 3D printing ever make race cars more comfortable? With some help from parametric design it might just happen one day.