How 3D printing is changing the way NASCAR builds cars

In context: As NASCAR and other motorsports continue to push the boundaries of performance and innovation, 3D printing is playing an increasingly crucial role. With its ability to produce complex, customized parts quickly and cost-effectively, additive manufacturing is changing the competitive landscape.

In 2021, NASCAR ushered in a new era with its Next Gen platform, introducing sweeping changes to the sport's iconic vehicles. The latest NASCAR cars now feature fully symmetrical designs and composite body panels, bringing them closer in appearance to their street counterparts, such as the Chevrolet Camaro, Ford Mustang, and Toyota Camry TRD.

One of the primary objectives of the Next Gen platform was to level the playing field and reduce operating costs. Technique Chassis, the sole chassis manufacturer for the NASCAR Cup Series, now produces a modular offering in three parts. This standardization means all teams start with the same foundation, forcing them to seek competitive advantages in the minutest details.

Enter 3D printing, or more accurately, additive manufacturing. Minnesota-based Stratasys has emerged as a key player in this area, recently earning the title of "Official 3D Printing Partner of NASCAR" and extending its 20-year partnership with the Joe Gibbs Racing team.

There are stark differences between hobby-level 3D printing and industrial-grade additive manufacturing, Fadi Abro, Stratasys Senior Global Director of Automotive & Mobility, told Popular Science. "Additive manufacturing represents robust industrial solutions," he said. This process involves creating objects layer by layer, in contrast to traditional subtractive manufacturing methods.

The advantages of additive manufacturing in NASCAR are significant. Stratasys can provide crucial components such as ducts, covers, brackets, and tubing due in large part to the flexibility of the platform. "You get a lot more freedom of design," Abro says. If you're cutting into a block, you can't make a 90-degree turn, limiting your shapes and designs... We always say complexity is free with the additive process, whereas in the more traditional methods, complexity can really increase the price and the lead time."

At the heart of this technological revolution are advanced materials like ULTEM 9085 and plant-based Nylon11, each chosen for their unique properties that cater to the demanding environment of professional racing. ULTEM 9085, a high-performance thermoplastic, stands out for its exceptional strength-to-weight ratio and impressive heat resistance. With a glass transition temperature of 186°C and a heat deflection temperature of 153°C, ULTEM 9085 can withstand the extreme conditions inside a race car.

ULTEM 9085's flame-retardant properties and aerospace industry certifications make it ideal for components requiring durability and safety compliance.

On the other hand, plant-based Nylon11 offers a more sustainable alternative without compromising on performance. Derived from castor beans, Nylon11 boasts superior mechanical properties compared to its petroleum-based counterparts. Its high impact resistance, flexibility, and ability to maintain strength even at low temperatures make it particularly suitable for parts that undergo constant stress and vibration during races. The material's low moisture absorption and chemical resistance further contribute to its longevity in the harsh racing environment.

The manufacturing processes employed by NASCAR teams have also seen significant advancements. Fused Deposition Modeling (FDM) and Stereolithography (SLA) technologies are now at the forefront of part production. FDM, utilized in printers like the Stratasys F370, 450mc, and F900, excels in creating robust, functional parts by extruding thermoplastic filaments layer by layer.

This method enables the production of complex geometries that would be challenging or impossible to achieve with traditional manufacturing techniques.

Stereolithography, on the other hand, offers unparalleled precision and surface finish. The Stratasys Neo800 SLA printer, recently added to NASCAR's arsenal, uses a laser to cure liquid resin into solid parts. This technology is particularly valuable for creating aerodynamic components and wind tunnel testing models, where even the slightest surface imperfection can affect performance data.

The precision and speed of 3D printing have proven invaluable in NASCAR's high-pressure environment. Abro recounts an incident where Joe Gibbs Racing encountered an ill-fitting tube component. Using 3D printing, they quickly produced a custom fixture, identifying the problem and reporting it to their vendor. This process, which might have previously required time-consuming and expensive CNC machining, was completed efficiently and cost-effectively.

"The thing that these teams never have is extra time," Abro said about NASCAR's fast-paced world.

Many of the 3D-printed parts used by Joe Gibbs Racing are ducts, crucial for managing airflow. These components play a vital role in creating downforce, cooling engines, regulating driver temperature, and even creating drag for sharp turns.

As the technology continues to evolve, Abro predicts that the next frontier in 3D printing will focus on increasing throughput. "If you need a hundred different versions of something, you don't want a hundred printers side by side," he said. "You want to get the five to ten printers that you have printing faster."

3D printing for custom car modification is expanding beyond NASCAR. At SEMA's annual showcase, a small shop called Blazin Rods demonstrated the potential of this technology by creating the "Doughboy," a heavily modified 1970 Chevrolet Chevelle featuring numerous 3D-printed parts. This innovative approach earned them SEMA's Best Engineered Vehicle award.