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Windform 3D printing composite materials from CRP Technology have been utilised in the development of the Deltawing race car, which has been designed to perform at the same level as other Le Mans prototype vehicles but with half of the available horsepower.

At the design level, this meant the car could only have half the mass and half the drag of the normal race vehicles.

To make the car work, an extreme weight-loss programme was initiated. However, time was very short, with only seven months from design to first track test.

The team used 3D printing technology together with Windform high-performance materials where applicable to speed up manufacturing time and to save as much weight as possible.

Key information

  • Laser-sintered Windform XT 2.0 was used in tooling, prototyping and testing, in areas including brake inlets and ducting, air inlet ducting, filter enclosure and the BLAT (underbody extension flange).
  • It was also utilised in mission-critical applications on the car, including bespoke electronics enclosures, electrical breakout boxes, transmission seal covers with integrated pressurised oil feed passages and the tow hook plinth.
  • Windform XT 2.0 was also used to construct the gearbox side covers.
  • Deltawing engineer Zack Eakin said the fact that Windform XT 2.0 could be used as a raceable part at the elevated temperatures and pressures the gearbox oil is run at opened up design possibilities that previously would have been too expensive in both time and cost.
  • The use of 3D printing and Windform materials were fundamental to shortening the timing of car construction.

CRP Group

The CRP Group is composed of six companies: CRP Engineering, CRP Meccanica, CRP Racing, CRP Technology, CRP Service and CRP USA.

The CRP Group is made up of specialized companies (CRP MeccanicaCRP TechnologyEnergica Motor Company, plus its US-based partner CRP USA) dedicated to providing clients with the very latest technological solutions.

The CRP Group has its headquarters in Modena, Italy’s renowned motor valley.

From 1970 CRP is a pioneer in the world of international motorsports and a hub of excellence for its state- of-the-art technologies.

With more than 45 years of experience in the world of F1 and more than 20 years of experience in Additive Manufacturing, CRP Group is distinguished by its know-how in specific application fields including but not limited to: automotive and motorsports, design, aerospace, UAVs, marine, entertainment, defense, and packaging.

CRP Meccanica provides High Precision CNC machining for industries as motorsports, automotive, aerospace, space and marine. It also offers services to companies that require a high level of customization and accuracy. The CNC center at CRP Meccanica maintains the latest CNC technologies and practices in the industry.

CRP Technology offers part production for short- and low-run production, and prototyping services with advanced 3D Printing and Additive Manufacturing solutions. As a material provider, CRP Technology develops, manufactures and sells its proprietary material Windform® for Laser Sintering.

Based in Mooresville, North Carolina, CRP USA is partnered with CRP group.

CRP USA resides in the heart of the southern industrial and manufacturing hub, and is surrounded by growing aerospace and motorsports communities.

CRP USA manufactures on-car and wind tunnel components for racing teams and has taken this expertise to new heights to produce parts for the space, entertainment and automotive sectors using Windform® materials and Additive Manufacturing.

In 2010 the CRP Group decided to invest in the new field of sustainable vehicles by creating Energica.

CRP Group acted as a technology and financial incubator, and it is still today the lead investor of Energica Motor Company, since it has become an independent entity. The Italian company of high-performing electric motorcycles has been chosen by Dorna as single manufacturer for FIM Enel MotoE™ World Cup.

Ego Corsa, the Energica’s electric racebike for the FIM Enel MotoE™ World Cup, will be developed through CRP Group’s know-how.

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