Professional Motorsport World
  • News
    • A-E
      • Bodywork
      • Business Services
      • Chassis
      • Circuit News
      • Data Capture
      • Driver Safety
      • Electric Motorsport
      • Engine Technology
    • F-N
      • Karting
      • Legislative
      • Logistics
      • Materials
      • New Competition Car
    • O-S
      • Off Road
      • R&D
      • Race Series News
      • Safety
      • Show News
      • Simulation
      • Single Seaters
    • T-Z
      • Team News
      • Tin Tops
      • Tyres
      • Transmissions
      • Workshop
  • Features
  • Online Magazines
    • October 2024
    • September 2023
    • 2022
    • September 2021
    • Archive Issues
    • Subscribe Free!
  • Opinion
  • Videos
  • Supplier Spotlight
  • PMW Expo
LinkedIn Facebook Twitter
  • Automotive Interiors
  • Automotive Testing
  • Autonomous Vehicle
  • Automotive Powertrain
  • Tire
  • Media Pack
LinkedIn Facebook YouTube Instagram
Subscribe
Professional Motorsport World
  • News
      • Aerodynamics
      • Bodywork
      • Business Services
      • Chassis
      • Circuit News
      • Data Acquisition
      • Driver Safety
      • Electric Motorsport
      • Engine Technology
      • Karting
      • Legislative
      • Logistics
      • Materials
      • New Competition Car
      • Off Road
      • R&D
      • Race Series News
      • Safety
      • Show News
      • Simulation
      • Single Seaters
      • Team News
      • Testing
      • Tyres
      • Transmissions
      • Workshop
  • Features
  • Online Magazines
    1. October 2024
    2. September 2023
    3. 2022
    4. September 2021
    5. April 2020
    6. Subscribe Free!
    Featured
    9th October 2024

    In this Issue – October 2024

    Online Magazines By Lawrence Butcher
    Recent

    In this Issue – October 2024

    9th October 2024

    In this Issue – September 2023

    21st September 2023

    In this Issue – 2022

    4th October 2022
  • Opinion
  • Videos
  • Supplier Spotlight
  • PMW Expo
LinkedIn Facebook Instagram YouTube
Subscribe
Professional Motorsport World
Features

Case Study: 3D Printing

John O'BrienBy John O'Brien28th May 20154 Mins Read
Share LinkedIn Twitter Facebook Email

CRP USA explains

how its additive layer manufacturing was the ideal solution for the DeltaWing project

The transition between the 2012 and 2013 season brought significant change to the DeltaWing. An entirely new operating team, crew, engine, and tire partner made for several new elements as the team took to the track. There is very little time between races to make necessary changes to a car, and the DeltaWing Racing Cars team and Élan Motorsports were faced with having to design a new engine from scratch.

Understanding the design and time constraints, when it came to the intake manifold, design engineer Christian “Skitter” Yaeger, turned to CRP USA to assist on the design and production.

The result of their combined efforts: from nothing but a Mazda head to a new running engine in 81 days, to racing at Sebring in 105 days – including a 3D printed intake manifold. (Left)

DeltaWing Innovative Design and Additive Manufacturing

The introduction of the DeltaWing in 2010 brought radical innovation and progressing efficiency to the racetrack. When the DeltaWing took to the racetrack, the engineering team pushed the boundaries of conventional design and launched a revolutionary approach in motorsports. Yet, it is with the new DeltaWing that took to the track in 2013, that is pushing the boundaries of efficiency, technology and innovation. Engineers at DeltaWing Racing Cars, working with CRP USA and Windform, created a component that is fully functional in the race industry. The result was an intake manifold designed and developed by DeltaWing Racing Cars utilizing additive manufacturing (3D Printing) technology with Windform SP for its construction, to operate under boost utilized in race conditions. The resulting component has been campaigned by the team since March 2013, gaining positive results and showing the tremendous potential for utilizing advanced materials technologies in partnership with 3D Printing.

“We could not have made this motor happen if we couldn’t produce parts directly from CAD files,” said Christian “Skitter” Yaeger, design engineer for DeltaWing Racing Cars. “The biggest benefit is being able to print exactly what you need. We have eight odd-shaped ports in the head, and CRP USA was able to match them perfectly, with a knife edge in between.

“With the coupe version, we went slightly less wild, and a little more conventional in our design,” continued Skitter. “Over the past two years, the 3D Printed manifolds have covered over 12,000 testing and racing miles, along with 6 hours per unit running on the dyno.”

Material Strength Ideal for Racing Conditions

Prior to the production of the intake manifold, Windform was used on the DeltaWing to produce several different components such as electronics enclosures, and transmission seal covers with integrated, pressurized oil feed passages.

As the engineering began the redesign of the intake manifold, a high performance material was required to handle the heat and tension placed on the part. CRP USA introduced Windform SP to the DeltaWing engineering team for consideration. Windform SP is a composite polyamide based carbon-filled material.

Windform SP has excellent mechanical properties and an added advantage of increased resistance to shocks, vibrations, deformations, and most importantly, Windform SP is resistant to absorption of liquids and moisture.

“The packaging constraints required by the location of the engine within the chassis requires some creative design,” said Stewart Davis, director of operations, CRP USA. “The runner lengths attach at the base of the plenum and form a complex structure that would be extremely difficult to build without using additive manufacturing. Windform SP’s toughness and heat deflection temperature allow the part to be built and then raced in the endurance series. The engine is run under boost, so it sees pressure variation in addition to the vibration, shock, and temperatures changes associated with racing.”

“The work done by Skitter and the DeltaWing/Élan Motorsports team is a great example of the application of Windform for a complex problem, and utilizing Additive Manufacturing to push the boundaries in racing,” concluded Davis.

Share. Twitter LinkedIn Facebook Email
Previous ArticleStrakka Racing switches to Dunlop ahead of Le Mans
Next Article Majority share of BBS GmbH sold to NICE Holdings

Related Posts

Features

Exclusive interview: F1 2026 with Haas’s Ayao Komatsu

5th July 20256 Mins Read
Features

The rigorous quality assessment behind every Bugatti W16 Mistral

3rd July 20254 Mins Read
Features

The critical role of DIL simulation in F1

2nd July 20258 Mins Read
Latest News

Shell and Nissan Formula E Team continue Formula E technical partnership

10th July 2025

Alpine unveils its first electric customer racing car – the A290 Rallye

8th July 2025

Bcomp, Porsche Motorsport and Four Motors unveil natural-fiber components in GT3 Cup car

7th July 2025

Receive breaking stories and features in your inbox each week, for free


Enter your email address:


Supplier Spotlights
  • ZF Race Engineering GmbH
Getting in Touch
  • Contact Us / Advertise
  • Meet The Editors
  • Download Media Pack
  • Free Weekly E-Newsletter
Our Social Channels
  • Facebook
  • Instagram
  • YouTube
  • LinkedIn
RELATED UKI TOPICS
  • Automotive Interiors
  • Automotive Testing
  • Autonomous Vehicle
  • Automotive Powertrain
  • Tire
  • Media Pack
© 2025 UKi Media & Events a division of UKIP Media & Events Ltd
  • Terms and Conditions
  • Privacy Policy
  • Cookie Policy
  • Notice & Takedown Policy

Type above and press Enter to search. Press Esc to cancel.

We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. By clicking “Accept”, you consent to the use of ALL the cookies.
Cookie settingsACCEPT
Manage consent

Privacy Overview

This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.
Necessary
Always Enabled

Necessary cookies are absolutely essential for the website to function properly. These cookies ensure basic functionalities and security features of the website, anonymously.

CookieDurationDescription
cookielawinfo-checkbox-necessary1 yearSet by the GDPR Cookie Consent plugin, this cookie records the user consent for the cookies in the "Necessary" category.
elementorneverThe website's WordPress theme uses this cookie. It allows the website owner to implement or change the website's content in real-time.

Advertisement

Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. These cookies track visitors across websites and collect information to provide customized ads.

CookieDurationDescription
OAGEOsessionOpenX sets this cookie to avoid the repeated display of the same ad.
OAID1 yearCookie set to record whether the user has opted out of the collection of information by the AdsWizz Service Cookies.
test_cookie15 minutesdoubleclick.net sets this cookie to determine if the user's browser supports cookies.
VISITOR_INFO1_LIVE5 months 27 daysYouTube sets this cookie to measure bandwidth, determining whether the user gets the new or old player interface.
YSCsessionYoutube sets this cookie to track the views of embedded videos on Youtube pages.
yt-remote-connected-devicesneverYouTube sets this cookie to store the user's video preferences using embedded YouTube videos.
yt-remote-device-idneverYouTube sets this cookie to store the user's video preferences using embedded YouTube videos.
yt.innertube::nextIdneverYouTube sets this cookie to register a unique ID to store data on what videos from YouTube the user has seen.
yt.innertube::requestsneverYouTube sets this cookie to register a unique ID to store data on what videos from YouTube the user has seen.

Analytics

Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.

CookieDurationDescription
CONSENT2 yearsYouTube sets this cookie via embedded YouTube videos and registers anonymous statistical data.
vuid1 year 1 month 4 daysVimeo installs this cookie to collect tracking information by setting a unique ID to embed videos on the website.
_ga1 year 1 month 4 daysGoogle Analytics sets this cookie to calculate visitor, session and campaign data and track site usage for the site's analytics report. The cookie stores information anonymously and assigns a randomly generated number to recognise unique visitors.
_ga_*1 year 1 month 4 daysGoogle Analytics sets this cookie to store and count page views.

Functional

Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features.

CookieDurationDescription
__cf_bm30 minutesCloudflare set the cookie to support Cloudflare Bot Management.

SAVE & ACCEPT
Powered by