High-Functioning Custom Brake Parts for Motorsports
Brake air ducts that are 3D printed from Forward AM materials resist high temperatures, withstand heavy loads, and promote performance.
CARLAYERS uses parts designed by SPEED Engineering and made with Forward AM’s Ultrafuse® PA GF30 glass-filled filaments to produce low volumes of brake ducts that direct air and prevent overheating during motorsports events.
Project Breakdown
Industry & Application
Automotive
Product
Ultrafuse® PA6 GF30
Technologies Used
Fused Deposition Modeling (FDM)
Why Forward AM Solutions and Materials?
Forward AM supplied the material and support needed to 3D print automotive parts quickly and cost-effectively.
Key Numbers
Over 1000 high-performance vehicles have installed these parts. CARLAYERS reports a 30 to 40% time-savings during production due to the larger material spools, which can be used well in the operation of a printer farm. Brake air duct reliability has risen to 95% thanks to the very consistent material quality.
CARLAYERS GbR of Hövelhof, Nordrhein-Westfalen, Germany uses 3D printing to produce small production runs of high-quality parts at unparalleled speeds. SPEED Engineering GmbH of Edisonstraße, Bielefeld, Germany asked CARLAYERS to 3D print brake air ducts.
In partnership with Forward AM, CARLAYERS used 3D printing to produce low volumes of these safety-critical parts. In addition to supplying Ultrafuse® PA6 GF30, a glass-reinforced thermoplastic, Forward AM shared its additive manufacturing expertise.
The Challenge
Brake air ducts are passageways that force air through internal vanes to lower the temperature of disc brakes. This forced air is coupled with the centrifugal force produced by the spinning of the discs to draw additional heat that can impede braking.
To promote performance during motorsports events, brake air ducts must work well with a race car’s vehicle body. Ducts that guide air flows specifically to the brakes can reduce temperatures while keeping brakes functional for longer.
High temperatures can reduce disc brake performance, but air ducts must also withstand high loads whenever race cars brake at high speeds. Traditional manufacturing methods can produce low volumes of custom parts, but they’re time-consuming and expensive to make.
The Solution
CARLAYERS considered Selective Laser Sintering (SLS), but the 3D printing technique would incur high costs and create excessive waste. Fused Deposition Model (FDM) requires material only where it’s needed and speeds post-processing because there are fewer support structures to remove.
During material selection, CARLAYERS experimented with PET-CF, but determined that PA6 was a better base material, especially with thinner wall thicknesses. Forward AM’s Ultrafuse® PA6 GF30 supports FDM and contains 30% glass fiber for strong, heat-resistant parts.
CARLAYERS chose a solution that supports threaded inserts. Before custom brake air ducts were shipped, these 3D printed parts were easy-to-assemble. CARLAYERS liked the consistent quality that Ultrafuse® PA6 GF30 provided and credited Forward AM for its technical resources.
The Result
As a premiere provider of 3D printed parts, CARLAYERS is supplying the motorsports industry with custom brake air ducts that resist high temperatures, withstand heavy loads, promote performance, and increase liability. From rush orders to bridge production, CARLAYERS wins the race.
Next Steps
Reference Links and Documents
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