July 4, 2022

Sauber Engineering AG, a division of the historic motorsport workers Sauber Workforce, has instructed Steel AM that it intends to determine a 3D printing enterprise enterprise for manufacturing on-need classic car spare sections. 

Harnessing the understanding gained from its 28 12 months-stint as a Technique 1 group, Sauber Engineering is now looking for to established up an organization, which supplies to reverse engineer and print spares for heritage automobiles. The brand new enterprise is designed to sort out the desires of traditional automotive lovers, whose prized belongings want mend, however can not rely on the aftermarket steering of indigenous suppliers. 

“At Sauber, we now have a wealth of information and comprehending of automotive engineering,” acknowledged Christoph Hansen, Director Engineering & Innovation at Sauber Engineering. “Mix this with our sensible expertise in AM for significant-general efficiency F1 components, and we can provide the historic automotive sector something unique – a one-halt-store to trade damaged or destroyed components that will or else imply the conclusion for that automotive or truck.”

“We will now present the traditional auto proprietor a assortment of decisions, from straightforward plastic handles as much as complete gearbox housings or engine areas.”

Sauber has presently managed to 3D print a substitute element for a Ferrari 340 America Barchetta. Impression through RM Sotheby’s.

Sauber’s motorsport heritage 

As a result of truth it was began in 1970, Sauber has developed up a storied background of motorsport good outcomes, wherein it has launched the Silver Arrows title again to the race hold observe of, and received the 24 hours of Le Mans. Sauber’s F1 workers has additionally taken element within the exercise repeatedly contemplating that 1993, bringing family 865 components within the technique, and it continues to race below the Alfa Romeo Racing ORLEN banner to this working day. 

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In extra of the final three a few years, Sauber’s partnership with Alfa Romeo has seen it steadily combine additive created components into its race vehicles. In 2020, the group’s ‘C39’ model highlighted 143 3D printed components, however this has now been ramped-up to 304 for this season’s ‘C41,’ in a system that’s approximated to have minimized their price ticket by 90%. 

The weather themselves have been crafted using Additive Industries’ machines at Sauber’s Steel 3D Printing Competence Coronary heart, which now residences 13 strategies that generate 22,000 components every calendar yr. Leveraging its creating AM capabilities, which features a few new AM Choices S1 post-processing programs, Sauber is now searching for to make the most of its F1 information elsewhere, within the restoration of timeless automotive classics. 

Christoph Hansen, Director of Technology & Innovation of Sauber Engineering, with Stephan Rösler, President & CEO of the Rösler Oberflächentechnik GmbH. Photo via Rösler Group.
Sauber has partnered with AM Solutions to bolster the publish-processing of its 3D printed race automotive components. Picture by utilizing the Rösler Group.

Renovating an automotive traditional 

Upfront of the launch of its new providers, which is able to supply customers each little factor from 3D printed covers to engine sections, Sauber has beforehand been challenged with making a gearbox housing for a primary Ferrari 340 America Barchetta. Geared up as normal to the automotive’s rear axle, the broken ingredient may no for an extended time be modified due to to its sheer rarity, when its age meant that its schematics couldn’t be sourced both. 

“The gearbox was poorly weakened and break up throughout the casing,” acknowledged Hansen. “Our solely alternative was to reverse engineer the housing, which included an entire 3D scan of the framework after which optimization of the CAD file to create a mode that could possibly be additively created.” 

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By way of the reverse engineering course of, Sauber Engineering’s group leveraged their prosperity of automotive expertise to assemble a re-made gearbox, which not solely highlighted the in-constructed tolerances important for stop-use operation, however was ultimately in a position of outperforming the unique. 

Developed making use of an Additive Industries MetalFAB1 3D printer at Sauber Engineering’s Zürich facility, the following aluminium element took round 5 days to create. When printed, the half was subjected to submit-processing and stringent screening, in the middle of which it proved to be each equally lighter and way more lengthy lasting than its genuine Ferrari-created predecessor. 

“Our function with Sauber’s new historic car items enterprise enterprise is to maintain these outdated classics alive, on the road and remaining employed for what they have been being developed for,” concluded Jonathan Herzog, Sauber’s Head of Endeavor Administration & Income. “By using at present’s know-how we are able to get hold of this, making sure these vital and far cherished historic automobiles and vehicles don’t vanish.”

3D printing spares and repairs 

The convergence of reverse engineering procedures, digitized inventories and 3D printing are considerably enabling the redesign and producing of unusual or discontinued components. Earlier in 2021, SOLIZE launched that it was working with HP as facet of an identical enterprise, to additive manufacture spares for a few of Nissan’s NISMO line of heritage sports activities actions automobiles and vehicles.

Within the earlier, British restoration workforce, Redesign Sport has additionally used 3D scanning and CAD modelling to reverse engineer a primary Ferrari. The enterprise used a Creaform system to scan components of a classic 1952 Ferrari 225 prematurely of outsourcing their era, and becoming them to the automobile all set for its presentation on the Goodwood Revival pageant. 

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In different places, equal reverse engineering methods have been deployed by the U.S. Army Aviation and Missile Command (AMCOM) to completely 3D mannequin a UH-60L Black Hawk helicopter. By making a digital twin of the transport airplane, the U.S. Army goals to arrange a catalog of digital components, which in flip, could possibly be utilised as a implies of 3D printing a few of its way more complicated-to-source components. 

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Highlighted graphic displays a Ferrari 340 The usa Barchetta. Picture by the use of RM Sotheby’s.