You can’t really avoid additive manufacturing (AM) in motorsport these days. It’s everywhere, and for good reason. AM is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to traditional ‘subtractive’ manufacturing methodologies. It is well-understood that AM gives engineers far more freedom to produce components with complex shapes. It also has the potential to deliver a more significant impact on technology and manufacturing for industry than almost any other technology to date.
Motorsport is a constant exercise in continuously improving performance within rapid time-frames, so it’s not surprising to find that this advanced manufacturing technology is a crucial element in implementing new designs and technology. As Michael Fuller, CEO and founder of Conflux, which specialises in AM heat exchangers, says: ‘With AM, freedoms are simply realised in hitherto un-manufacturable geometries.’
The ‘sweet spot’ for AM lies in where designers want to create a component with only the required structures for its application, and optimise its size and weight. For example, designing hollow tubes and I-beams inside a component can help create a stiff internal structure with minimal weight.
How parts are loaded determines where material needs to be present, and often the centreline of a structure doesn’t require any material, as the outside of the part carries the stress. ‘The key element is the part’s application, as this will dictate the technology, material, and any post processing requirements to ensure it is fit for purpose,’ says Samuel Persaud, head of projects at Graphite Additive Manufacturing.
‘Design for manufacture considerations is more relaxed for AM, allowing far greater ability to design without many of the constraints traditional manufacturing has,’ Fuller adds, ‘Limitations of imagination and creativity are common and, as with any industrialised manufacturing technology, foundational training in design for additive manufacturing is a critical success factor for
