Sahara Force India F1

The pace of Formula One (F1) development is rivalled only by the speeds achieved on the racetrack. Each time the Sahara Force India F1 Team brings its car to a circuit, it represents the team’s top engineering; every time the team leaves, the car is just a baseline. Between races it must be reoptimised to outperform the last, best version.

“F1 is essentially a development race,” says Patrick Hawtin, Rapid Manufacturing Leader, Sahara Force India F1 Team. “Once the cars are on the track, that’s one thing, but every single week we’re trying to bring more performance to the car.”

Sahara Force India F1 is based at Silverstone and Brackley in the UK, and has relied on 3D printing as a crucial component of its development process for more than 17 years.

Particularly useful for wind tunnel testing, 3D printing has saved Sahara Force India F1 considerable time and money in the development and testing of new designs. Before 3D printing, not only was manufacturing more labour intensive, with pattern and composite shops providing tooling, carbon layering, curing, trimming and finishing, but the design process was also slower and more involved to accommodate these extra steps.

Using the previous workflow, it took 5-7 days to produce one testable design. From a development standpoint where 20 or more iterations of a design are needed for testing, these traditional methods simply were not scalable.

Sahara Force India F1 has relied on 3D printing as a crucial component of its development process for over 17 years.

“The benefits of using 3D printing in our design and development come down to cost, lead-time and quality,” says Patrick Hawtin, Rapid Manufacturing Leader, Sahara Force India F1 Team. “3D printing gives us the capacity to make hundreds of parts in a week, and when we go through the wind tunnel testing we do, there’s no way we could develop parts at the same rate without 3D printing unless we quadrupled the size of our more traditional manufacturing departments.”

Sahara Force India F1 predominately uses 3D Systems Stereolithography (SLA) for its wind tunnel tests. Hawtin says it is not just the throughput of the 3D Systems SLA printers that make them an asset, but also the accuracy and resolution of the systems to meet their target requirements.

“3D Systems’ SLA systems deliver accuracy within a tenth of a millimetre,” Hawtin says.








 Sahara Force India F1 Team’s Rapid Manufacturing Department works closely with the team’s design, aerodynamic and other manufacturing departments to devise new designs in multiple iterations. The team’s engineers use 3D Systems’ stereolithography machines with a range of 3D Systems materials selected to meet their application requirements, including Accura Bluestone, Accura Greystone and Accura 60. These applications include windtunnel model parts, full-size parts, moulds, cores and jigs.

“We use SLA printing for airfoil sections and downforce testing, which require extremely smooth surfaces,” says Hawtin, adding that the temperature resistance of Accura Bluestone also makes it good for carbon moulding.

“3D Systems’ SLA systems allow us to survey more and benefit from the sensitivity we can achieve with many iterations,” says Hawtin. “The amount of finesse we’re looking for would be lost if we did it any other way.”

Hawtin concludes: “The current pace of F1 development would be pretty much nonexistent without 3D printing.”

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