Stewart-Haas Racing drives innovation with 3D printing in motorsports

A recent exploration of the advancements in additive manufacturing within the realm of motorsports highlights significant innovations being made by Stewart-Haas Racing through its collaboration with 3D Systems. The partnership, which spans three years, aims to leverage cutting-edge 3D printing technologies to enhance the performance and speed of the team’s racecars.

Stewart-Haas Racing’s production manager, Reneau Van Landingham, vividly recounts the transformative effect that the introduction of a stereolithography (SLA) machine had at their North Carolina facility. He initially approached the new technology with caution, uncertain whether it could deliver parts rapidly and reliably. However, Van Landingham noted that “Wednesday night, we would deliver parts to the tunnel, ready to be tested at six in the morning the next day, just in time.” The fast-paced demands of motorsports necessitate precise timing, and the ability to produce accurate parts quickly has become essential for their competitive edge.

John Murray, Vice President of Global ISG Segment & Business Development for 3D Systems, emphasises the intense nature of motorsports, stating, “No one pushes harder than motorsports teams. It’s a 24/7 job feeding these wind tunnels that have enormous appetites.” This relentless drive for innovation allows for rapid learning and development, providing Stewart-Haas Racing with tools to explore new materials and manufacturing processes that can be applied across multiple industries.

The adoption of the ProX 800 and Figure 4 Standalone 3D printers has enabled the NASCAR team to create highly intricate parts, significantly accelerating their prototyping capabilities. Van Landingham elaborates on this shift, stating, “Now, printing hundreds of parts like that over a few weeks’ time is not only possible but it’s kind of normal.” The ability to efficiently prototype various aerodynamic shapes is vital for optimising car performance during wind tunnel testing sessions, where every second and every part counts.

The diversity of materials offered by 3D Systems has also expanded, allowing engineers to create items ranging from functional prototypes to production parts like TV camera components and pit tools. “With these printers come materials that we weren’t used to using,” Van Landingham explains, revealing how this evolution has led to the development of parts such as gaskets and flexible connectors that were previously unattainable.

3D Systems has also invested in creating specific materials for aerodynamic testing, like the Accura Composite PIV, which serves a crucial function in Particle Image Velocimetry testing. “It’s very purposely purple,” Murray noted, pointing out that this colour choice aids in the accuracy of test measurements by minimising laser reflection errors.

In the high-stakes environment of NASCAR, where the races occur weekly, the advantage derived from rapid prototyping is immense. Van Landingham articulates the pressure to perform, saying, “Our most precious commodity is time. We race every weekend… we’re racing between the races against our competitors to design and 3D print parts for our race cars for that next race.” This inter-race competition is critical in maintaining relevance and enhancing the team’s performance.

This initiative is further supported by the growing interest and expertise among the younger engineers at Stewart-Haas Racing, who have familiarity with 3D printing technology from their formative years. Murray notes the importance of leadership in harnessing such innovations, stating, “You can have all the machines and all the resin you want, but you have to have people with vision.”

As the team looks towards the future, they are already considering further advancements. Van Landingham has expressed eagerness for the 3D Systems PSLA 270 high-speed, projector-based system, which promises to combine the precision of SLA with faster printing capabilities. He articulated the ambition succinctly: “If we could just 3D print the whole car, that would be great.”

This ambitious goal underlines the growing influence of additive manufacturing technologies within competitive environments, demonstrating how they are reshaping business practices in the motorsports industry and beyond. The collaboration between Stewart-Haas Racing and 3D Systems illustrates the potential of such innovations to drive efficiency, performance, and ultimately, competition in high-speed sports.

Source: Noah Wire Services