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 new rear wing element. Production is for an update to the 50 cars already being raced and the further expected production of 100 plus units. We then created a CAD box with the upper and lower limits of the regulations allowed. The new wing is then designed within these parameters.
A CFD test to make sure we the actual pressures met what the calculations showed was done to check our design.
Next Prototyping, for this part we CNC machined a negative former so that a single (or low volume production run) could be made. This was then fitted to a test car and run at a closed day on a track, to check its performance.
After that test a crash test was carried out, the wing is designed to break in 2 places should a rear shunt happen, or a trip backwards into the tyre wall. This is due to the low lap's and quick turnaround from race 1 and 2 where fixing time was too limited. Whilst the remaining wing produced less downforce a black flag was avoided. Now we had the prototype we returned to our negative mould and made a GRP former over all of it and an extra width to form a lip to bolt the 2 halves together. These formers, when removed, were used to make the production mould, not wasting them afterwards they are trimmed to use as fitting jigs. removed at the end of the day and returned to us for manufacture. The total cost of the design, development and moulding 950, the finished composite parts were 120 each for however many units totally 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, the original wing was scanned to get span and chord, and fittings for the uprights are also measured.
- Stage Three The championship reg's are entered first to make sure our part fits within the allowed dimensions.
- Stage Four Computational Fluid Dynamics, (CFD) calculations were made on this model although limited by reg's, we checked for problems.
- Stage Five Prototyping, using our CNC milling machine we made a A + B mould, layered in roven wovings and injected in foam in 4 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, and approved. Next we make a production mould, a trim jig and a fittings jig, used to mount the captive nuts which will allow it to be bolted to the uprights.
- Stage Eight Production parts, 100+ production numbers and designed to break in a controlled manner the finished part production will be in GRP Woven Mat, similar to carbon fibre in appearance and make up, an alternative production method is sprayed plastic for the surface and foam core.".