Much better! Sauber Motorsport optimizes the post-processing of SLA parts

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Rösler Oberflächentechnik GmbH 3D post processing technology

FAULHABER Drive Systems

Sauber Motorsport relies on a C1 Max from AM Solutions – 3D post processing technology for the post-processing of parts printed via stereolithography (SLA) using 3D Systems ProX 800 machines.

The components produced by Sauber Motorsport using SLA are highly complex and require maximum precision, it is stated. This is already explained by the application spectrum of the components, as they are used almost exclusively in the wind tunnel for Formula 1, which is crucial for the dynamics of a vehicle. To reliably and quickly deliver high-quality 3D-printed parts for this purpose—about 1,000 parts per week from October to February—efficient post-processing is also needed. In the SLA area, Sauber previously had to carry out many steps manually for the chemical post-processing. This not only cost a lot of time with seven printers but was also a significant burden on employees who had to work with chemicals. Since February, however, they have been using two C1 Max from AM Solutions, which have eliminated these problems, it is further stated.

Post-processing effort for 3D printed parts was halved

The C1 Max is based on the concept of the C1 and was specifically adapted by AM Solutions to the needs of Sauber Motorsport for the use of large build platforms, as noted. The SLA prints are submerged into the treatment basin via an automatically lowering build plate and surrounded by a specially tempered medium. A propeller, in combination with multiple individually controllable nozzles, ensures ideal flow and maximum flexibility in post-processing. A mesh basket guarantees that no parts are lost or damaged in the immersion bath. A well-coordinated interaction of chemical, thermal, and mechanical processes softens the support structures, allowing them to be easily and gently removed afterward. (Previously, each individual component had to be laboriously worked by hand with a spatula using extensive PPE equipment). As Sauber notes, this reduced the post-processing from a whole day to half a day.

Post-processing agent spares the environment and employees

The specially developed medium used in a C1 Max is said to be more environmentally friendly than conventional agents, which also positively impacts the health of employees, who can now work in the room without masks. A significant practical advantage is that no additional equipment is needed when emptying the system. Once the medium is saturated, it is safely pumped out via the integrated pump and disposed of by a service provider. Overall, the cleaning effort for the system has been significantly reduced compared to before, according to Sauber.