Welcome to a new approach
Our advantage over any competition, and the reason it actually works as a system is that it is all carried out under one roof, so minimizing error and keeping continuity with all the stages and systems integrating smoothly and passing the collected or created information in digital format.
This integration makes the process viable, with it all under one roof all down the line the very first digital information we capture is done with the very last process of the chain in mind.
To the right is the process of making a set of dive planes, the customer only had 1 car and wanted 3 pairs, budget as often is the case was limited. However because the left and right are just mirror images we only have to design one, and then just mirror it. So we scanned one corner only taking point data collected in under 5 mins all on battery power, at a race meeting we happened to be at. We then created a diveplane limited by regulations, fit, form and function only one design was realistic, a quick CFD test to make sure we hadn't missed an opportunity to improve the design and then over to the Rapid Prototyping plastic printer. It was at this stage for the first time that the mirror option was used to make the opposite side, therefore cost had been limited to just one design. Now we had a pair of parts they were fitted and tested live on a normal trackday meeting to further reduce cost. The digital on-board data showed a small improvement but more importantly the driver had more confidence on turn in and made up a second a lap. The prototypes were removed at the end of the day and returned to us for manufacture. A rubberised mould was made from the RP parts and then an epoxy plastic was pumped into the mould under low pressure. The total cost of the design, development and moulding 300, the finished epoxy parts were 12 each for however many required.
utilising technology, at its best, under one roof, to the full.
- Stage One Project Briefing. First of all we need to know what is required and what its aim is. Then we can work out viability + process.
- Stage Two Digital data gathering of placement of the part in its finished location. Here a dive plane on a front bumper.
- Stage Three An estimation of required form, function and fit is made. Then using CAD we create a surfaced model.
- Stage Four Computational Fluid Dynamics, (CFD) quick calculations were made on this model as we knew what to expect from experience.
- Stage Five Rapid Prototyping, using our Stratasys Titan SRP plastic printing machine we made a left and right part in a few hours.
- Stage Six Real world testing, prototype parts are fitted and tested. With on-board data collected live from before and after.
- Stage Severn Tested, modified if required, and approved the prototype part is used to make a production mould. As it is low volume a rubberised mould is made for low pressure plastic injection keeping costs down.
- Stage Eight Production parts, low production numbers and collision factors for the finished part, so we made the finished dive planes in epoxy plastic. Almost as light as carbon fibre but able to flex in the event of "rubbing is racing".