The ‘formula’ behind Formula One is a series of complex rules and regulations that must be adhered to by the competing drivers and teams. The rules frame a technological window within which each team produces a car, all within a maximum permissible budget. The regulations create a fiercely competitive landscape where fractions of a gram here, a micron or two there, and the overarching speed of development separate podium finishers from the ‘also rans’. To help excel in this harsh competitive environment, McLaren deploys Stratasys‘ stereolithography 3D printing technology through a suite of five Neo®800 3D printers ? producing full-size aerodynamic surfaces to high-accuracy embedded sensor housings ? to chase the ideal design for the road ahead. Formula One is synonymous with aerodynamics. While computer-aided design (CAD) and computational fluid dynamics (CFD) are keys to the design and development of a Formula One car, wind tunnel testing is still the gold standard when assessing how every surface works together, either as an assembly or as a complete car. McLaren uses only the FIA permissible 60% scale models of parts in its wind tunnels to optimise the aerodynamic package and find more downforce ? which provides more aerodynamic grip ? and balance the front and rear aerodynamic loads on the car.
PerFORM Reflect was developed specifically for wind tunnel models. It creates strong, stiff parts that, when combined with the surface fin...