How 3D-Printed Parts Changed the NASCAR Cup Series

Longtime Slashdot reader schwit1 shares a report from Popular Science: In 2021, NASCAR unveiled its Next Gen platform that included a number of rule changes from the previous iteration. Now fully symmetrical and using composite body panels instead of metal, the latest NASCAR vehicles are more like the street versions of the Chevrolet Camaro, the Ford Mustang, and the Toyota TRD Camry. Race car driving isn't an inexpensive sport, and one of the goals for the Next Gen platform was to reduce operating costs and create parity across the board. Technique Chassis, the sole chassis manufacturer for the NASCAR Cup Series, builds a modular offering in three parts. As a result, everyone is starting with the same platform, and finding a competitive advantage is in the tiniest details. One smart way to differentiate from the competition is 3D-printed parts. But this isn't your hobbyist level 3D printing.

Minnesota-based Stratasys specializes in 'additive manufacturing,' the process of creating an object by building it one layer at a time. Stratasys Senior Global Director of Automotive & Mobility Fadi Abro explains that this term is synonymous with 3D printing. However, the industry often reserves that description for hobby-level projects on smaller, non-industrial printers, while additive manufacturing represents robust industrial solutions. Additive manufacturing is the exact inverse of subtractive manufacturing, which requires cutting away at a solid chunk of material to achieve a final product. In art terms, additive manufacturing would be like sculpting with modeling clay while subtractive is akin to carving a shape from a block of marble. As it relates to NASCAR, Stratasys provides parts like ducts, covers, brackets, and tubing. Together with the racing organization, Stratasys reviews the current driver needs and makes recommendations for other parts and modifications.

The kind of printers Stratasys builds aren't the type you buy at your local electronics store, either. Each industrial-grade 3D printer costs anywhere from $20,000 to $600,000. Using this kind of equipment isn't without precedent, and builds at SEMA's annual extravaganza feature 3D parts we wouldn't have dreamed of a few years ago. In the past few months, Stratasys has been on a roll, signing an extension to its 20-year partnership with the Joe Gibbs Racing team and earning the title of 'Official 3D Printing Partner of NASCAR.' Competition for this market continues to heat up, however, as there are startups and legacy companies pushing hard. Around the world, 3D printing companies abound. Stratasys has one major factor on its side: 35 years of experience. What's new is that today's printing is more accurate, it's faster, the materials are more robust, Abro says. 'I think what's changed drastically over the past five to seven years has been all about material development,' Abro explains. 'We're seeing materials that are just incredible, whether it's how resistant to heat they are or how strong they are compared to how much they weigh.'

'It's better, faster, cheaper. It's faster to print something than to mill it, and then it's certainly cheaper in a multitude of different ways. Number one, there's not as much skill required for 3D printing as there is in CNC machining; you need a more traditional manufacturing method.'

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