Rapid Prototyping & Additive Manufacturing

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1 Discover The Magic Of Unlimited Design Sauber Aerodynamik AG I I 2016 Page 1

2 Your Advantages Discover the magic of rapid prototyping What is Rapid Prototyping? Rapid Prototyping (RP) is magical. In conventional machining processes, matter is removed from a solid material such as wood or metal in order to reach the desired shape (for example, by milling or eroding machines). Additive RP processes open up unimagined opportunities, right down to the fast and cheap production of small-series for even the most complex of components (additive manufacturing). Additive processes build up the desired shapes in layers by means of a "3D printer". Selective laser sintering (SLS) uses a powder as the starting material and a laser "sinters" the object layer by layer. Stereolithography (SLA), is based on a laser hardening a liquid resin in layers to let the desired part arise. Advantages Of Rapid Prototyping Rapid prototyping offers the following advantages compared to conventional production processes: Unlimited shaping (undercuts, cavities, complex geometries) Tangible, fully functional parts within the shortest time Excellent cost vs benefit ratio Areas Of Application In motorsport, RP parts are even used for racing on the track. Our experts are looking forward to assist you with their advice. The most important fields of application at a glance are: Prototype testing Design models, sample parts Installation and clamping devices Pilot and small series parts Test parts for wind tunnel testing Motor racing (brake cooling ducts, aero covers, etc.) Architecture, art Sauber Aerodynamik AG I I 2016 Page 2

3 We have what you need. Machine Park And Building Space Use us. With a total of 11 large-volume production machines, our machine park offers one of the largest capacities in Europe. By so-called "splitting" and subsequent bonding, we are able to manufacture parts that are larger than the building (or installation) space shown below. Type of machine Building space 1) Number of machines SLS / selective laser sintering 500 x 500 x 750 mm 2 SLS / selective laser sintering 500 x 500 x 440 mm 4 SLA / stereolithographie 650 x 750 x 480 mm 5 1) Maximum size of parts without splitting; bigger parts possible by splitting & bonding Sauber Aerodynamik AG I I 2016 Page 3

4 Magic Powder! Selective Laser Sintering (SLS) When something is created from nothing. A powder is applied in thin layers on the building platform. The layers are sintered in the powder bed by a controlled laser beam according to the layer contour of the component. Subsequently, the building platform is lowered slightly and a new layer of powder is evenly spread. Advantages Of The SLS Method: High mechanical and thermal stress resistance of the parts Parts can be used immediately Simple mechanical finishing as no supporting structure needs to be removed Sauber Aerodynamik AG I I 2016 Page 4

5 Turn water into wine? Stereolithography (SLA) No. Creation of value. A photosensitive resin (photopolymer) is hardened by a laser in thin layers. The procedure is done in a bath which is filled with the base monomers of the photosensitive resin. Advantages Of The SLA Method: Very high accuracy Offers extremely high resolution Advantageous when producing parts with cavitites Sauber Aerodynamik AG I I 2016 Page 5

6 We have the right material for you! Our Materials We use the following materials of which the most important properties are: Parameter HiPAC (SLS) 1) Bluestone (SLA) 2) Xtreme (SLA) 3) Density laser-sintered at 25 C ca. 1,2 g/cm³ Density solid at 25 C 1.78 g/cm³ 1.19 g/cm³ E module bending 7327 MPa MPa MPa Flexural strength 132 MPa MPa MPa E module tensile force 8304 MPa MPa MPa Tensile strength 85 MPa MPa MPa Crack expansion 2.7 % % % Melting point C - - Heat resistance ca. 170 C 54 C Glas transition temperature C 1) HiPAC is a carbon-reinforced polyamide 12 developed by Sauber F1 Team 2) Accura Bluestone by 3DSystems 3) Accura Xtreme by 3DSystems Sauber Aerodynamik AG I I 2016 Page 6

7 Developed for Formula One. HiPAC At your service! HiPAC is a proprietary development for laser sintering by our company. It is based on a carbon-reinforced polyamide 12. PA 12 stands out due to its extremely low water absorption compared to other polyamides. It is therefore characterised by a particularly high dimensional stability and the minimal influence of moisture on its mechanical properties. Due to its unique properties, we use HiPAC in Formula One for various components of our racecars. For example, HiPAC-based brake cooling ducts are driven directly on the race track. HiPAC is resistant to: Petrol Oils and fats Esters Alcohols Ketones Ether Hydrochlorofluorocarbons Alkalis Diluted acids Sauber Aerodynamik AG I I 2016 Page 7

8 The Emperor's New Clothes. Customer-Oriented Finishing Not only because of beauty. Our parts are typically delivered in standard sandblasted raw finish. In addition, we offer the following individual surface processing: Polished Lacquered (matt, glossy, 1 or 2 K lacquer according to individual colour code) Plastered / laminated with foil Metal-coated Sauber Aerodynamik AG I I 2016 Page 8

9 Our Services In A Nutshell Our credo in Formula 1: Together we are strong! Let s team up! Besides the actual production of rapid prototyping parts we support you with the following additional service options: Consulting (processes, concept, design) Construction / CAD Quality assurance, right up to 3D scans Assembly or complete models (even large, complex assemblies up to the finished prototype) Coatings, pasting Express deliveries Sauber Aerodynamik AG I I 2016 Page 9

10 Trust us. Call us. What Can We Do For You? Contact Us Rapidly. Count on us: rely on decades of racing experience and expertise in rapid prototyping and problem solving! Our specialists are ready to advise you in all matters relating to our offers. Please contact us. Sauber Aerodynamik AG, Wildbachstrasse 9, 8340 Hinwil, Switzerland Your Rapid Prototyping Hotline

11 Sauber Aerodynamik AG Wildbachstrasse Hinwil Switzerland sauberf1team.com

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