July 6, 2022
The workforce at Sauber had been just lately challenged to construct a substitute gearbox housing for a Fifties Ferrari 340 America Barchetta (Courtesy Sauber Engineering)

Sauber Engineering AG, portion of the Sauber Workforce, is searching to enter the fundamental car ingredient provide enterprise with a assist in a position of providing reverse engineering and Additive Manufacturing of essential elements.

With an automotive historical past relationship again about forty years, Sauber will apply its information and know-how utilized in Formulation 1 to fabricate sections for traditional vehicles, precisely the place an aftermarket provide chain is confined, or no for an extended time exists.

Conversing to Metallic AM journal, Christoph Hansen, Director Technological innovation & Innovation at Sauber Engineering, was desperate to make clear the reasoning behind the enterprise. “At Sauber, we’ve a wealth of experience and understanding of automotive engineering. Combine this with our sensible expertise in Additive Manufacturing for large-overall efficiency F1 parts, and we may give the historic auto sector one factor distinctive – a one particular-end-store to vary damaged or weakened elements that might if not imply the conclusion for that automobile or truck.”

Sauber has each equally polymer and metallic AM machines at its facility in Zürich, Switzerland, and has been making use of them for a amount of yrs to supply the 2 prototype and working elements. “We are able to now give the classic automobile or truck proprietor a assortment of options, from simple plastic covers, as much as complete gearbox housings or engine elements,” further Hansen.

The rear axle gearbox was terribly broken and never attainable to fix (Courtesy Sauber Engineering)

Sauber Engineering AG, a part of the Sauber Workforce, is looking out to enter the fundamental automobile or truck factor present enterprise enterprise with an organization in a position of giving reverse engineering and Additive Producing of essential components.

See also  One of the best automotive care merchandise to have this summer season: Tire restore, detailing kits, cleaners

With an automotive historical past relationship once more in extra of forty a long time, Sauber will make the most of its skills and technological know-how utilized in Formulation 1 to fabricate items for traditional motor autos, precisely the place an aftermarket provide chain is proscribed, or no lengthier exists.

Chatting to Metal AM journal, Christoph Hansen, Director Know-how & Innovation at Sauber Engineering, was eager to elucidate the reasoning driving the problem. “At Sauber, we’ve a prosperity of understanding and understanding of automotive engineering. Combine this with our experience in Additive Producing for substantial-general efficiency F1 components, and we are able to provide the historic car sector one thing distinctive – a a person-stop-shop to substitute damaged or damaged components that might in any other case suggest the shut for that automobile or truck.”

Sauber has equally polymer and metallic AM tools at its facility in Zürich, Switzerland, and has been making use of them for a spread of a few years to create every prototype and performing elements. “We are able to now present the normal automobile or truck proprietor a wide range of choices, from simple plastic covers, as much as full gearbox housings or motor sections,” extra Hansen.

The crew reverse engineered casing was optimised for the AM method (Courtesy Sauber Engineering)
The re-made gearbox casing was additively made at Sauber Engineering’s Zürich facility (Courtesy Sauber Engineering)

That is wherever the wealth of automotive information at Sauber is important. “We all know what tolerances a gearbox wishes to be crafted to, we all know what provides are greatest to make use of. We are able to then implement our working expertise to design and magnificence the part, producing it not solely carry out, however incomes it perform significantly better than the first,” ongoing Herzog.

See also  ’85 Mazda RX7’s unique Walnut Creek proprietor hasn’t modified

In some circumstances, of sophistication, a ingredient might be fastened, however this was not attainable with the Ferrari gearbox. “The gearbox was terribly harmed and cut up all through the casing. Our solely risk was to reverse engineer the housing, which related a complete 3D scan of the composition after which optimisation of the CAD file to create a design that may very well be additively produced,” included Hansen.

The gearbox housing was developed in-residence making use of a MetalFAB1 system from Additive Industries. The MetalFAB1 is a Laser Beam Powder Mattress Fusion (PBF-LB) machine in a position of producing parts from a broad vary of metals, which embrace maraging or gadget metallic, aluminium, Scalmalloy, titanium and nickel alloys.

The additively made gearbox casing was machined to fulfill up with the required tolerances (Courtesy Sauber Engineering)

“The Ferrari gearbox was crafted from aluminium (AlSi10Mg) and took round 5 days of printing making use of our very personal in-home created higher-pace parameter set. It then underwent a amount of put up-processing features and inspections. Many due to our design optimisation, the closing half was truly lighter and extra dependable than the primary casing,” talked about Hansen.

“Our goal with Sauber’s new historic car elements enterprise is to maintain these aged classics alive, on the freeway and staying made use of for what they’d been constructed for. By working with in the present day’s engineering we are able to notice this, ensuring these important and an amazing deal cherished historic vehicles and vehicles don’t vanish,” concluded Herzog.

The crew at Sauber might be contacted via e mail: [email protected]

www.sauber-group.com/de/engineering/