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RPS is the official 3D Printing partner of Oxford Brookes Racing (OBR), providing Oxford Brookes University students guidance and 3D printed parts from a range of AM technologies and materials.

Under the guidance of RPS, OBR were able to use 3D printing applications on their Formula Student car that can be seen in high-performance industries and top-level motorsport such as Formula One.  3D printing has allowed OBR the freedom to create complex, intricate geometries and benefit from weight and time savings compared to the traditional methods used in the past.

Students from the aerodynamics team received 3D printed moulds using the NEO800 stereolithography system and DSM’s PerFORM resin.  The moulds were able to withstand the heat and pressure of an autoclave, suitable for carbon fibre layup due to the composite material. The benefits seen by the students were time savings and design freedom, superior sidewall quality and unmatched detail resolution that cannot be achieved using traditional manufacturing methods.

Laser Sintering technology and ALM’s PA 603-CF were also used on the Formula Student car. The technology and the materials allowed OBR to produce lightweight components with complex geometries and high dimensional accuracy while maintaining high stiffness and strength. ALM’s PA 603-CF can withstand the highest stiffness and heat resistance, perfect for wind tunnel model testing and high-performance racing.

OBR also worked with RPS to iterate the design of the intake plenum and OBR steering wheel using HP’s Multi-Jet Fusion technology and HP PA12 material. HP’s MJF technology gave the students the ability to create complex, internal and external structures. With the intake plenum, OBR saved over 52% in weight compared to previous years using Alumide. Benefits of MJF technology were also seen in the lightweight, ergonomic design of the OBR19 steering wheel.

This July, OBR19 are competing in the Formula Student competition and are looking to beat last year’s results where they were best in the UK and 2nd overall. The Formula Student competition will be held in Silverstone, 17-21 July 2019. Click here to read the case studies for all the 3D printing applications used on the OBR19 Formula Student car.