Off-road additive manufacturing: time saved on and off the track

A week before the race, the team prepared their Side by Side (SxS) vehicle to compete and win. Suddenly, during preparation, on Thursday afternoon, the antenna clamp broke. This is bad news and without a suitable replacement, communications between the crew and race officials break down, creating a very dangerous environment for the pilot. With less than 24 hours left until the end of the race week, it is impossible to produce and deliver a component on time. Adversity requires a creative solution.

This scenario is common for those who participate in all types of off-road sports. Racing teams are typically small and fueled by passion, so they tend to be cost- and resource-conscious when it comes to solving problems. Schwartz Off Road Motorsportz (Oshkosh, WI) is one of several family-owned teams competing in the Off Road Series, but their approach to engineering solutions is anything but common.

Erik Schwartz has been working with 3D printing since high school and knows the kind of value it can offer for quick answers to complex problems. By combining his passion for motorsports with an affinity for 3D printing, his team was able to do more with less. “Some people want to get into 3D printing,” Schwartz said. «Not me. Quality matters and when I get to print, I want it done right.» A few years ago, Schwartz and his team encountered several design and performance issues for the SxS vehicle and didn’t hesitate to integrate the Ultimaker 2. Since then, over 4,000 hours of printing have been accumulated and the team has moved on to the Ultimaker S5.

CHALLENGE

Passion on a limited budget is a real challenge for those who want to compete at a high level. For SORM and many other racing teams, it is imperative to build, test and optimize the vehicle within a reasonable budget. Traditionally, races are held every two weeks during a given season and changes are constantly made. Whether it’s repairing broken parts, replacing others, or improving the design to increase performance, it takes time and money. “When there’s a problem with a component, we usually take it to a machine shop,” Schwartz said. “It is expensive and can take up to three weeks to deliver.”

Like most racing teams, the SORM team has limited in-house manufacturing methods and must rely on third-party companies to produce sheet metal parts. Parts that require constant replacement of the vehicle due to wear and tear are brackets, fasteners, clamps and a variety of mounts. While some parts can last an entire season, others need to be replaced every weekend. “These pieces range from $500 to $750 each,” Schwartz said. “It’s hard to absorb these kinds of costs, especially when we need backups or make a design mistake. Let’s face it, we don’t always get it right the first time.”

Beyond the issue of replacing used parts, Schwartz and his team are constantly modifying and finding new ways to keep their vehicle competitive. Ideation is one of the key strengths, so the team had to find a cost-effective way to test ideas and validate the functionality of certain parts. Whether it’s developing lighter components or redesigning exhaust pipes, each new project can mean the difference between winning and losing. «Fans only get to see the 20 minutes on the track, but behind the scenes, our team puts a lot of time and effort during the week to make this happen. We need everything to go right,» Schwartz said.

The solution

Schwartz is a veteran Ultimaker user. For years, the team has owned and operated the Ultimaker 2 single-extrusion 3D printer. Using it primarily as a prototyping tool, the team printed in PLA to test form, fit, and functionality for a variety of ideas. After more than 4,000 hours of printing, the equipment still functions like new and has been a source of curiosity for enthusiasts and other racers. “We invite fans to the track and it’s always a topic of conversation,” Schwartz said. “Like the trailer or the toolbox, we treat the 3D printer as an important part of the business.” Used primarily for prototyping, Schwartz and his team knew an upgrade was in order: the Ultimaker S5 dual-extrusion 3D printer.

Early last season, a costly accident damaged the vehicle in multiple ways, forcing the team to replace the radiator. Due to supply chain issues, the manufacturer has indicated a payment deadline of six months. This was unacceptable and would have caused the team to lose their season entirely. Instead, Schwartz ordered a basic radiator and designed several consoles to fit the vehicle himself. The Ultimaker S5 was the perfect tool for printing and reprinting polycarbonate parts that attach to the metal brackets that hold the heat sink in place. “I was in a really great time,” Schwartz said. “The 3D printer saved our season and somehow made it better.” With a wide range of advanced materials at their fingertips, the team began using the equipment in ways they never thought possible.

Other applications and advantages of additive manufacturing in this sector

Complex features: Dual extrusion technology allows SORM to maximize the value of PVA (water soluble) material, especially for complex geometries or internal channels. SORM has developed an improved front grille designed to increase airflow to the vehicle, thus providing a natural cooling mechanism. Making a custom walkway like this is nearly impossible, but completely doable with bi-material 3D printing that combines the strength and functionality of polycarbonate with soluble PVA.

Organization: A workshop can be chaotic and sometimes the smallest details can save time, money and headaches. Printing custom color coded jigs, fasteners and trays has become standard on the SORM shop floor. Multi-color printing capabilities lead to a more organized workshop. This is a common practice for many larger industrial companies that use this technology to identify safety features and create robust ergonomic devices for workers.

Results and future prospects

“Materials and data,” Schwartz said confidently. Advances in polymer development have become a great boon to the industry. Stronger rubbers, customized plastics with chemical resistance properties and thermoplastics improved in terms of heat deflection will contribute to the advancement of the industry. Additionally, the data collected will improve part analysis and performance for future product development. The next generation of industrialization is highly connected, and data collection will impact how companies produce prototypes, spare parts and products.

Ultimaker is the emblem of innovation and continues to prove it. Its material portfolio boasts over 40 advanced filaments available directly from Ultimaker or accessible through a preferred network of suppliers. Additionally, CURA software is considered one of the most user-friendly and intuitive programs available to 3D printing engineers and the enthusiast community. By aggregating data, this software provides the industry with the tools to react faster and achieve superior performance. Similar to Schwartz Off Road Motorsportz, Ultimaker is committed to modifying, improving and performing at the highest level possible.