Our manufacturing processes

FDM-Print

We had our rear wing, front end, axle suspension and the guide lug of the prototypes for the test phase manufactured from polycarbonate by our sponsor FOERSTER using a 3D printer in the FDM (Fused Depostition Modeling) process. This rapid prototyping process enables the rapid production of precisely fitting parts from a high-strength material. The plastic is melted and the part to be printed is built up layer by layer. The necessary auxiliary and support structures are then washed out, allowing parts with very complex geometries to be manufactured. Polycarbonate parts manufactured using the FDM process are characterized by low costs, comparatively good surface quality and fitting accuracy, and short production times.

SLS-Print

Unsere Heckflügel, Front, Achsaufhängung sowie die Führungsöse für das finale Auto haben wir bei unserem Sponsor cirp mit einem 3D-Drucker im SLS-Verfahren (Selektives Lasersintern) aus  Polyamid-Pulver  fertigen lassen. Dieses Verfahren ermöglicht uns die schnelle Fertigung passgenauer Teile mit einer guten Oberflächenqualität. Dabei wird hoch stabiler Kunststoff mit Hilfe eines Lasers aufgeschmolzen und das zu druckende Teil Schicht um Schicht aufgebaut. Durch die Fertigung im Kunststoffpulver können die beim FDM-Verfahren nötigen Hilfsstruckuren wegfallen. Die im SLS-Verfahren hergestellten Teile zeichnen sich durch deutlich bessere Passgenauigkeit und Oberflächenqualität mit gleichzeitig hoher Stabilität aus

CNC-Milling

We milled our chassis on a 5-axis milling machine (Hermle C30u) at the Fischer company in Sindelfingen. The cars are milled from above and below. Our Solid Edge data was converted into a milling program with the hyperMILL software and Solid Works after detailed consultation with our sponsor Fischer. In total we had 6654 steps of production and one a one hour work-duration was necessary to achieve a perfect production quality for the chassis.

Rotating

We also manufactured the majority of our axle design in collaboration with our sponsor Fischer . Here we have opted for the manufacturing method of turning. The workpiece is turned and machined by a rigid tool to remove material layer by layer. Through this manufacturing process, a high manufacturing accuracy is achievable, which is essential for a perfect ball bearing seat.