The UVic Formula SAE Racing team is having their carbon fiber racing car parts 3D printed by CRP USA.

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**Introducing the Finalists: 3D Printing Industry Awards 2023**

*Winners to be Announced at London-based Awards Ceremony*

It’s that time of year again, folks! The prestigious 3D Printing Industry Awards 2023 nominations are now open, shining a spotlight on the leaders in the 3D printing industry. This year, the winners in twenty different categories will be revealed during a live awards ceremony in London on November 30th.

But what makes these awards truly special is the groundbreaking work being done by the nominees. Take, for example, CRP USA, a leading provider of 3D printing materials and services. They have recently joined forces with the University of Victoria’s UVic Formula SAE Racing team to push the boundaries of 3D printing in the automotive industry.

Together, CRP USA and UVic Formula SAE Racing team have embarked on a long-term collaboration to develop 3D printed carbon fiber-filled racing car components. Through the Laser Sintering additive manufacturing process, they have successfully produced integral parts such as the steering wheel and elements of the lubrication system using carbon fiber-filled composite Windform materials.

In a recently published case study, the two companies claim that 3D printing with Windform materials has allowed them to create functional parts that are not only versatile but also possess optimal mechanical properties. According to Luke Wooldridge, Powertrain Lead of UVic Formula Racing, these components have proven their durability on the track, even under extreme conditions.

Wooldridge recounts an incident where the racing car struck a traffic cone, shearing off the screw attaching the front wing to the chassis and bending the aluminum mounting arm. However, the 3D printed Wingform XT 2.0 insert on the other side remained undamaged, showcasing the exceptional resilience of these parts.

One standout component developed by the team is the new oil and water catch cans, which seamlessly integrate with the chassis packaging. These cans were 3D printed from Windform SP, a carbon fiber-filled composite known for withstanding high heat. During testing, these parts held up remarkably well, with no significant damage reported despite reaching temperatures of approximately 125°C for water coolant and 150°C for oil.

The steering wheel faceplate was also given a makeover using Windform XT 2.0. This carbon fiber-filled composite provided superior heat resistance, impact resistance, and durability compared to the in-house prints previously used. The hand grips, however, were crafted using Windform RL, a thermoplastic elastomer from the Windform range.

When it comes to the powertrain system, CRP USA has collaborated with the UVic team to create several iterations of the oil pan using Windform SP. This material’s impact resistance and high-temperature resistance have made it the ideal choice for the development of these crucial components. The flexibility of 3D printing has also allowed the team to reduce the overall height of the oil pan, resulting in improved weight distribution and on-track performance.

To further enhance the performance of their racing car, the UVic team incorporated anti-sloshing features directly into the 3D printed parts. One such example is the one-way baffle doors integrated into the oil pan. Additionally, CRP USA utilized Windform SP to 3D print a custom oil pick-up, complementing the oil pan design.

Aerodynamics play a vital role in any racing car, and the UVic racing team understands this well. They have successfully 3D printed front wing inserts using Windform XT 2.0, providing seamless attachment points for the front wing onto the chassis.

Lastly, the engine intake of the racing car, additively manufactured by CRP USA using Windform XT 2.0 in 2019, has proven to be a game-changer. Remarkably, this intake has withstood the test of time, lasting an impressive four consecutive seasons. With engine block temperatures reaching up to 125°C, the intake’s thermal stability has been crucial in ensuring the car’s reliability during competitions.

As you can see, the collaboration between CRP USA and UVic Formula SAE Racing team has pushed the boundaries of what can be achieved with 3D printing in the automotive industry. Their innovative use of carbon fiber-filled composite materials and the versatility of the additive manufacturing process has resulted in functional, durable, and high-performance racing car components.

So, mark your calendars for November 30th and join us in celebrating the winners of the 3D Printing Industry Awards 2023. We can’t wait to see who will emerge as the leaders in this exciting field. Stay tuned for more updates!

Additive manufacturing, also known as 3D printing, has revolutionized many industries, and motorsport is no exception. The development and production of cutting-edge racing cars often rely on this innovative technology to create high-performance components. One recent example of this is the 3D printed engine intake developed by CRP USA.

The new engine intake has undergone significant improvements compared to its predecessor. One notable change is the increase in volume, from 1.4L to 4.23L. This expansion allows for better airflow into the engine, optimizing its performance. But how was it made possible without sacrificing the quality of the printing process?

The secret lies in the 3D print resolution. The engineers at CRP USA were able to retain the necessary resolution for adding sealing surfaces and sensor mounting directly into the intake. This eliminates the need for post-machining, saving time and resources. By utilizing Windform XT 2.0, a high-quality 3D printing material, they were able to create a larger intake with improved functionality.

One major improvement that resulted from the enlarged intake is the transition from bent to straight intake runners. This simple change significantly improved the simulated efficiency of the air flow, boasting an impressive 100% increase. This means that the engine can breathe more easily, enhancing its overall performance.

The application of additive manufacturing in motorsport is not new. Many leading racing teams have integrated 3D printing into their production processes. For example, the BWT Alpine F1 team purchased four SLA 750 3D printers from 3D Systems, enabling them to produce components for wind tunnel testing. These printers utilize Accura Composite PIV material, which is ideal for creating high-quality, functional prototypes.

Similarly, McLaren Racing, a renowned British Formula 1 team, has embraced Stratasys’ 3D printing technology. With the help of five Stratasys Neo 800 3D printers, they are able to produce approximately 9,000 parts annually. These parts are used in various aspects of their car, including the aerodynamic racing car parts and the top-body and side bodywork. This adoption of 3D printing technology allows the team to iterate designs quickly and efficiently, giving them a competitive edge on the track.

In conclusion, additive manufacturing plays a crucial role in the motorsport industry, enabling the production of high-performance components with greater efficiency. The recent development of the 3D printed engine intake by CRP USA showcases the possibilities and advantages of this cutting-edge technology. With the ability to optimize geometry, improve airflow, and eliminate the need for post-machining, 3D printing continues to redefine what is possible in the world of motorsport and beyond.

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