Challenge: Promote automotive research and development to improve automotive performance in a constantly changing environment
Solution: 3D Systems' one-stop solution from printers, materials to applications
Results:
 A small team of engineers produced hundreds of components for wind tunnel tests in a week
Using 3D Systems' SLA and SLS printing technology, complex car parts can be produced within a few hours, while traditional methods require several weeks
More innovative parts design through 3D printed investment casting prototypes
 Better assembly quality can be obtained through the design and production of precision fixtures and fixtures. Traditional methods of production require a lot of time, or even impossible to produce.

 3D printed parts for testing and automotive use create new ways

Renault F1 Team opens up new innovative ways through R&D cooperation with 3D Systems
For Formula One, unremitting innovation is the source of its power. The team works tirelessly to achieve peak performance during the race, which is also the core spirit of the Renault F1 team. The key to whether the team can achieve the goal is the team's persistent pursuit of vehicle performance and the ability of technical partners.
Nick Chester, Technical Director of the Renault F1 Team, said: "Through race after race, through rigorous testing and selection of R&D and simulation experiments, vehicle components made of complex composite materials and aerospace alloys let us see It’s dawn. At the end of the season, we hope that the car can make one more lap per second than before. This is a very demanding requirement for our technical partners. But we cannot accept partners who cannot bring us vehicle performance improvements. ."
Continuous innovation, active collaboration and rich 3D printing experience are one of the main reasons why Renault Racing chose 3D Systems.
The Renault team in Enstone, UK, has been using 3D Systems technology in its core operations since 1998. As an early user of 3D printing prototypes, the fleet's use of 3D printing is also based on the development trajectory of 3D printing technology. In the early days, it was mainly used in the verification of function and fitting design and the production of fixtures and fixtures for precise assembly.
As the cooperation continues to deepen, 3D Systems' application engineers have helped Renault Motorsport use 3D printing technology more deeply. The team’s ability to conduct wind tunnel tests will also have a positive impact on the cooperation between the two parties and the innovation of auto parts through 3D printing investment casting.

Technical Director Chester said: “The support Renault Team received from 3D Systems is also constantly changing with its technological progress. If we look back, you can find that with the improvement of material performance, the team has 3D printed The application has expanded to more engineering fields. The number of 3D printed auto parts has been increasing year by year. In terms of design versatility, reduced production time and cost reduction, the fleet has benefited a lot."

3D printed investment casting prototypes help to obtain large and complex metal parts faster
The 3D Systems equipment recently used by the Renault team includes 2 SLA printers and 3 selective laser sintering SLS printers. Materials related to: Accura materials used to make fixtures & fixtures, liquid flow devices, investment casting prototypes; DuraForm PA materials used to make wind tunnel test parts; DuraForm GF materials used to make auto parts such as electric boxes and cooling channels .
From matching materials to improving efficiency through better design, the cooperation between Renault Racing and 3D Systems has driven more outstanding performance on the field.
-- The pace of chasing speed never stops --
Every year, the Renault team designs and manufactures a new car to respond to the changes in the rules of the race. This is also their constant innovation in order to improve car performance. For example, changes in racing rules will bring many challenges. The 2017 season update includes larger and heavier tires, wider front wing, lower and wider rear wing and higher diffuser. This means that the 2016 season The used parts cannot be used in the 2017 season.

Once the season begins, the pressure will continue to escalate: sometimes only a short week is available for engineering changes to components. From dedicated tracks to street races, each race brings great challenges to engineers in terms of structure, climate, and track type.

3D Systems' SLA technology enables Renault Team to quickly respond to engineering changes
-- Quick verification design --
From the beginning, 3D printed prototypes have proven to be very useful in making compact race car interior parts. The Renault team quickly saw the potential of 3D printing in the field of fitting and functional testing, because they noticed that 3D Systems' equipment can make extremely complex parts. Aware of these, they began to make more use of 3D printing technology, gradually extending from rapid prototyping to wind tunnel model manufacturing.
Warner mentioned: "In wind tunnel tests, aerodynamics is an empirical science. We design and compare new concepts to choose a design direction. The more design concepts we compare and evaluate, the more likely we are to win. Big. "In terms of component quality, equipment running time and output, 3D Systems’ SLA equipment is a great boon for the productivity required by the fleet.
-- Drive the development of dynamics through the development of wind tunnel tests --

The Renault team's aerodynamics department has grown significantly in recent years. So far, there are 120 aerodynamicists, wind tunnel technicians and model builders. Warner said this is largely due to the use of 3D Systems' 3D printing technology. He introduced the complex internal runner technology into the design of the wind tunnel test model. This is an important influence brought by the 3D Systems technology and an opportunity to obtain more pressure readings.

3D Systems' metal printing facilitates the innovative exploration of auto parts
Warner said: "The vehicle model in the wind tunnel test is in a complex pressure sensing network. Before SLA technology is used, metal and carbon fiber components need to be located by drilling holes. Now we can make a complex flow inside. The entity of Tao has completely improved the ability to place more sensors. This is like an aerodynamicist’s dream come true."
Warner estimates that a single wind tunnel test requires 600 3D printed parts per week, completed by a team of 5 engineers from Advanced Digital Manufacturing (ADM).
Warner said: "We can't follow the usual practice."
"We need a comprehensive company to meet our needs. 3D Systems can provide a one-stop service. We can get the equipment, materials and expertise that 3D Systems application engineers have."
-- Manufacturing speed and precision of auto parts --
In terms of productivity and efficiency, 3D printing has significantly improved the Renault team's ability to cope with different competition environments. Using SLA and SLS technology, complex fixtures and fixtures, liquid flow devices, and auto parts can be manufactured in a few hours instead of weeks. This makes 3D printing technology an ideal choice for Formula One racing cars.
In addition to testing a large number of auto parts in wind tunnel tests, Renault Team also directly manufactures some auto parts. Rob White, Chief Operating Officer of Renault Racing, mentioned: "3D Systems' technology provides us with a new and efficient process, which allows us to shorten production time and reduce costs, adding tremendous value to the team. One On the one hand, we are thrilled to be able to perform several iterations on the same part in wind tunnel tests. On the other hand, we also notice that more sintered parts are used in actual vehicle manufacturing every year."
3D printing helps the team to make parts that are lighter and improve speed and fuel efficiency. At the same time, it can also be used as an accurate flow test. In addition, it can improve engine performance and reduce wear. Once the design is completed, the sample data and selected materials will be produced by the ADM department. Using SLA and SLS technology, the efficiency of manufacturing complex auto parts is much better than before.
SLA prototypes are becoming more and more common in applications such as gearboxes and suspension components, so the design and creation of team engineers is more unrestricted. The SLA process has high precision, which not only saves a lot of time in the production of prototypes, but also saves a lot of time in post-processing.
-- New ways of racing car development --
The advantages, experience and services of 3D Systems technology are closely linked to the important tasks of the Renault team, including innovation, productivity optimization, accuracy and precision improvement. For Bob Bell, the chief technology officer of Renault Racing, 3D Systems is not just a technology supplier. The team has a good partnership with 3D Systems and will jointly explore the huge potential of 3D printing.
"The cooperation between us and 3D Systems has allowed us to be more productive and more efficient in the past 20 years. 3D printing has opened up new production methods, and I believe that the future will be better."