In pole position with 3D-manufactured wheel carriers

Formula Student is an international design competition for students who design, build and drive Formula 1-style racing cars. One of the top teams in the series is the racing team from Esslingen University of Applied Sciences. It is supported by the BENSELER subsidiary 3D Laser BW GmbH und Co KG: the 3D specialists from Kirchheim unter Teck supply ultra-lightweight wheel carriers and rocker shafts, which are manufactured using the metal laser melting process.

As in Formula 1, every gram that the students save in the construction of their racing car counts in the Formula Student race against the clock. And of course, as with the professional cars, all the parts used must be able to withstand high loads - especially if they are relevant to safety. This is where the Esslingen University racing team excels. In the Formula Student Electric world rankings, the team is among the top ten of over 300 participating universities. In addition to the performance of the young designers and drivers, this success is also thanks to the suppliers, who develop high-tech components with the students and support them with their expertise. The 3D specialists from 3D Laser BW in Kirchheim unter Teck, a subsidiary of the BENSELER Group, are also on board. They supply wheel carriers and rocker shafts that are manufactured using the metal laser melting process and are therefore bionic and many times lighter than comparable components manufactured using other processes such as investment casting.

Small wall thicknesses possible in metal laser melting
Using the metal laser melting process (also known as LaserCUSING^®, DMLS, SLM, LPBF), 3D Laser BW manufactures, among other things, near-contour cooled tool inserts for die casting, injection molding and functional prototypes. In this process, metal powder is applied in layers and melted with a laser beam. This means that even unusual component geometries can be produced efficiently and without tools. For the first time in its history, the Esslingen University racing team has installed an inverted wheel carrier manufactured using the metal laser melting process in its current racing car. In a conventional wheel assembly, the hub is located inside the wheel carrier, whereas in the inverted wheel assembly it is the other way around. Compared to conventional processes, the new wheel carriers from 3D Laser BW are many times lighter. This is because the metal laser melting process allows significantly thinner wall thicknesses to be achieved than with conventional casting processes. Another advantage of the 3D process is the integration of functions: elements such as cables can be integrated into the components, which would have to be placed around the component with conventional parts. In addition, the printed wheel carriers and rocker shafts are stronger than the cast models. This is a significant advantage for the Esslingen University racing team in the race for thousandths of a second.

Sources: Esslingen University of Applied Sciences and 3D Laser BW