Prototype parts provide a racing advantage

A Moog product story

Edited by the Engineeringtalk editorial team Mar 4, 2002

3D Systems has joined forces in a technology and marketing alliance with USA based Penske Racing for its NASCAR Winston Cup programmes.

3D Systems has joined forces in a technology and marketing alliance with USA based Penske Racing for its NASCAR Winston Cup programmes.

Penske Racing uses 3D Systems solid imaging technology to build prototype parts for Winston Cup Series cars driven by Rusty Wallace and Ryan Newman.

The process enables Penske engineers to produce new parts easily and quickly from CAD data - a necessity for making quick adjustments to improve the performance of their cars between racing events.

As part of the marketing alliance, Penske uses an SLA 5000 system and a ThermoJet solid object printer from 3D Systems.

The machines, in use and on display at Penske Racing headquarters in Mooresville, NC, create concept models, visual aids and wind tunnel models, as well as aid in the production of final assemblies fitted on the racecars.

"3D Systems' advanced technology allows us to be extremely flexible with our vehicle design and manufacturing", said Nelson Cosgrove, Lead Engineer for Penske Racing.

"ThermoJet printer models are used as direct tooling for investment castings that are finish-machined and put into service on our racecars.

We can make numerous changes to parts between production runs without major tooling costs".

Ideal for building concept models, the ThermoJet printer sprays layers of thermoplastic material to create solid objects.

For Penske's production and testing process, the high-end SLA 5000 system builds parts using a laser that hardens liquid plastic layer by layer, forming three-dimensional models from digital designs of engine components, aerodynamic surfaces and other complex part geometries.

"Penske Racing competes 36 weekends a year, and each of our teams has seven two-day test sessions.

This does not allow for long-lead research and development", Cosgrove said.

"With the SLA 5000 system, we are able to produce prototypes of body, chassis and powertrain components.

It's all about having flexibility to respond to design changes in the shortest time, and 3D Systems is an integral part of our process".

According to Cosgrove, the SLA system allows Penske Racing to create highly detailed components for the aerodynamic research programme.

"Many of the pieces that we create for the wind tunnel model have integrated pressure tappings, which allows us to measure pressure changes in components that would have been impossible with other manufacturing methods".

"Stereolithography has some clear advantages over carbon fibre or fabricated aluminium components when it comes to flexibility and ease of manufacturing", Cosgrove added.

"The SLA 5000 system gives Penske Racing the tight accuracy required for scale model testing, giving us an immediate competitive advantage".

"The Penske Racing alliance is a high-profile example of our global mission to provide strategic technology to market leaders in all industries", said John Murray, Senior Director of Global Business Development for Motorsports.

"The Penske teams consistently have proven their competitiveness by blending creativity and technology.

They are known for embracing cutting-edge processes that give them unique competitive advantages - a strategy that matches with the versatility and speed of our systems.

We look forward to celebrating many more Penske Racing team wins".