Frame up

The first race series in the world to use advanced additive manufacturing technology to produce a safety-critical system on its cars

IndyCar’s new Aeroscreen will be under close scrutiny this year as it makes its race debut, but the extraordinary device has already been extensively tested and both organisers and manufacturers are confident it will pass muster on track.

The device is made up of a 3D printed titanium framework designed by Red Bull Advanced Technologies (RBAT) and built by Austrian company Pankl. The screen is developed by PPG and is designed to protect the driver against small part intrusion into the cockpit.

However, the tube structure on which the polycarbonate is mounted is a work of art. Weighing just 12.25kg (27lb), the titanium top bar is made from five 3D printed pieces welded together in a form that resembles the Halo safety device that has been widely adopted in FIA-sanctioned racing.

Several manufacturing methods were considered in the first instance as the development cycle began. The initial design was made for titanium casting (Ti-casting), but it became apparent that the timeline to produce the volume of Aeroscreens needed for the first race of 2020 was too tight to use that method. 3D printing then became the most feasible option and Pankl, as a well-known racing industry tier one supplier, became the chosen partner for industrialisation.

The Aeroscreen assembly consists of four sub-systems: carbon fibre