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Product category: Rapid Prototyping
News Release from: Moog FCS | Subject: Accura SI 40
Edited by the Engineeringtalk Editorial Team on 06 January 2003

High-temperature material aids F1
prototypes

3D Systems will showcase its latest generation of SL material for the SLA stereolithography system at next week's Autosport International exhibition.

3D Systems will showcase its latest generation of SL material for the SLA stereolithography system at next week's Autosport International exhibition The new SL material - Accura SI 40 - is designed to improve the functional testing of rapid prototype and digitally manufactured components, and is the first material on the market to combine high temperature resistance with toughness

3D Systems already offers durable SL materials, but toughness is a separate characteristic from durability, and toughness with high temperature resistance is a rare combination.

Until now, traditional SL materials used for producing rapid prototype components have either provided high temperature capabilities or toughness, but never both.

The new optically clear material is particularly suited to under the hood applications as well as other motorsport applications such as wind tunnel testing and flow analysis.

It also allows parts to be produced with a 'high flexural modulus elongation' and with a 'high heat deflection temperature' allowing components to be drilled, self-tapped and bolted on for improved functional testing.

Commenting on its latest material development, Mike Kelly, European Sales and Marketing Director for 3D Systems said: "The ability of this new generation of SL material to produce more robust and heat resistant parts will further improve the functional testing capabilities of rapid prototype and digitally manufactured components.

Moreover, Autosport International is the ideal exhibition at which to launch our latest stereolithography material developments to the European motorsport industry".

Visitors to the 3D Systems' stand will be able to see a comprehensive example of how Accura SI 40 has the potential to benefit motorsport teams.

On display is an F1 transmission, complete with internal rotating parts, which has been assembled using the new material.

The type of tests that could be contemplated for this 'see through' gearbox include mounting it on a rig for simulating G-forces in order to visualise how the lubricant moves, allowing the oil flow to be optimised and thereby ensuring it reaches all vital areas.

3D Systems' technology is already being used in other F1 applications, including the development of a new head and neck support (HANS) system for Jaguar Racing.

The ability to produce accurate prototypes directly from CAD data has allowed the team to design its new HANS system, a compulsory safety feature for the 2003 season, in record time and to meet the individual requirements of its drivers.

In addition, 2002 saw 3D Systems announce a contract to supply and install a range of its stereolithography and selective sintering systems (SLS) at the Advanced Digital Manufacturing Centre being built by the Renault F1 Team at its headquarters in Enstone, Oxfordshire.

The installation at the centre, due to be completed early in 2003, will allow the Renault F1 Team to make the most of its expensive wind tunnel investments to improve the aerodynamics and therefore competitiveness of their racing cars.

The unique solid imaging technology employed by the Renault F1 Team provides a major improvement in the build quality of components over traditional modelling techniques and part finishing processes as accurate models are produced direct from CAD input.

In addition, the speed of 3D Systems solid imaging technology will allow Renault F1 Team designers and engineers to produce working component prototypes quickly and cost effectively allowing them to test more options and explore new possibilities in between each race meeting.

The process offers a high level of precision - permitting the smallest changes in geometry of less than 0.01mm - and repeatable dimensional accuracy, thereby enhancing the value of wind tunnel data for aerodynamic refinement.

3D Systems technology also provides a unique process for directly integrating pressure tappings into wind tunnel models.

Complete front wing assemblies, for example, can be manufactured overnight with as many as 120 integrated pressure tappings.

In addition to providing technology products, 3D Systems offers engineering consultancy services and can provide a team of highly skilled specialists to work directly with motorsport clients.

(This was Engineeringtalk's Top Story on 3 January 2003).

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