Automotive AM

3D Systems’ Figure 4 EGGSHELL-AMB 10 material speeds up development for BWT Alpine F1 Team

The team runs multiple builds a day on its Figure 4 Modular for a wide range of casting tools for on-car parts and testing

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3D Systems’ Figure 4 EGGSHELL-AMB 10 material is reportedly providing BWT Alpine F1 Team with unprecedented access to high-performance molded parts for record-speed development. In February this year, the team purchased four SLA 750 systems from the company.

3D System’s Figure 4 EGGSHELL-AMB 10 material helps to produce a diverse range of high-quality molded silicone and polyurethane parts at record speed – providing access to one-off and iterative parts using conventional molding material; and sacrificial tooling with the flexibility to deliver final parts in a range of silicones, polyurethanes, and other materials such as metals and ceramics.

In addition to this, the BWT Alpine F1 Team also runs multiple builds a day on its Figure 4 Modular for a wide range of casting tools for on-car parts and testing. Pat Warner, BWT Alpine F1 Team’s advanced digital manufacturing manager, estimates that most 3D printed eggshell molds print in just 90 minutes, with the largest builds taking up to three hours.

3D Systems’ Figure 4 EGGSHELL-AMB 10 material speeds up development for BWT Alpine F1 Team. The team runs multiple builds a day.
3D Systems printers at the BWT Alpine F1 Team’s ADM center.

Finally, 3D System’s 3D Sprint, the all-in-one software for polymer 3D printing, provided BWT Alpine F1 Team with a straightforward CAD-to-casting workflow. The software’s extensive toolset includes options for adding supports as well as for managing the printing process.

“With these solutions I’m seeing things every day that I’ve never seen before. I can’t think of another way we could make this many different components in this many silicone and PU materials at this relentless of a pace,” said Pat Warner, Advanced Digital Manufacturing Manager for the BWT Alpine F1 Team. “The performance demands on Formula One parts are extreme. Races take up to two hours, during which the entire vehicle is subjected to wildly varying temperatures, intense vibration, and brutal forces. It’s a horrible environment to put something you haven’t seen before yesterday, and we are always striving for perfection. We must ensure that all our parts perform the tasks they are given.”

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746 composites AM companies individually surveyed and studied. Core composites AM market generated over $785 million in 2023. Market expected to grow to $7.8 billion by 2033 at 25.8% CAGR. This new...

Edward Wakefield

Edward is a freelance writer and additive manufacturing enthusiast looking to make AM more accessible and understandable.

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