Rapid Prototyping and Rapid Manufacturing
Time is a precious resource, particularly in F1.
Rapid Prototyping procedures (Layer Manufacturing Technique) allow a finished mock up to be obtained in a short amount of time, in order to make functional, fluid-aerodynamic, fitting and assembling tests.
For instance, a 1 to 1 scale aerodynamic model, complete with rear mirrors and helmet, has been realized for F1 wind tunnel testing.
CRP is a pioneer in RP applications, having started in 1996 with the RP technology analysis, when it was almost unknown in Italy, and it developed new cutting edge materials.
In fact, CRP soon had to face the lack of suitable materials to develop their ideas and Franco Cevolini explained: “RP was a fast, cost effective way to realise new design concepts; it allowed us to create practically perfect 3D shapes. Nevertheless with standard materials the models would had been too fragile to work with referring to the applications we had in our mind.
Therefore, in 1996, we understood that it could be possible
to manufacture stronger prototypes, suitable for wind tunnel tests, but
it was necessary to develop better performing materials. I mean, the
Rapid Prototyping potential was assumed but the powders structural properties had to be improved. Therefore,
thanks to research and experimentation we made the WINDFORM ® range”.
WINDFORM ® materials, commercialised worldwide, are used for the majority of parts produced for wind tunnels models, and are very appreciated because of their
long-lasting performances and stiffness, so that they can be directly used for the race cars parts too. The worldwide interest in CRP’s research has enabled the company to create in 2001 a
specific department for new materials development, managed directly by CRP Technology Material Engineer and Technical Director, Franco Cevolini.
WINDFORM ® XT,
carbon fibre filled, allows the creation of high-end functional prototypes and production parts, the real challenge for the other RP materials, and so far unsurpassed, therefore leading to
Rapid Manufacturing applications.
WINDFORM ®
can also be CNC machined, it is dimensionally stable and is used by constructors
to build and evaluate complete sub-assemblies before finally committing to a design.Customers are looking for performance, quality and repeatability but within ridiculously short delivery times: they are looking for
Rapid Manufacturing.
Materials manufacturers have worked hard to improve parts’ properties and quality, to be closer to the market needs, and CRP created the
WINDFORM range, while machine producers are trying to obtain repeatability.
A huge step forward has been achieved: now with laser sintering technology and
WINDFORM materials it is possible to use layer manufacturing techniques not only to manufacture functional testing models, but also
high-end prototypes and small volume production parts can be sintered: this is exactly
Rapid Manufacturing.
“High mechanical and thermal properties were developed to allow a shift from simple concept models to finished parts, while the Quality policies are applied in order to hold the performance closer to production technologies and suppliers: these are the last requirements for end-users and service providers looking for Rapid Manufacturing”, Franco Cevolini explains once again.
Rapid Manufacturing has a great engineering and projecting power: together with a staff with in depth materials, manufacturing and engineering knowledge, it allows the development of high performing products, even through several improving subsequent steps, within extremely short time to market, and without affecting too much the investments made at the beginning.
CRP Technology RP & RM Department, one of the biggest service bureaus in the world, supports the customer with the choice of the material best suiting his needs and with the design optimisation, in order to exploit better this new technology. Moreover, a specific sandblasting and finishing method has been established for the parts, which are therefore delivered with surface and detail definition beyond comparison.
The system doesn’t require any support because the piece is held up by the non sintered powders, therefore giving a complete freedom of shape.
Rapid Manufacturing 
