Case Study: Lotus F1 Team achieves race-ready mass production of parts with 3D Systems

Lotus F1 Team and 3D Systems move together towards race-ready mass production of parts

Lotus F1 Team, together with 3D Systems, faced the challenge of rapidly developing and producing complex, tightly packaged race components that must survive extreme temperatures, vibrations and rigorous wind‑tunnel validation. The team needed faster iteration and more precise internal geometries for sensors, plus a cost‑effective path from rapid prototyping to race‑ready production.

By deploying 3D Systems’ SLA and SLS technologies and creating an Advanced Digital Manufacturing centre with nine rapid‑manufacturing systems, Lotus moved from prototype testing to direct part manufacture. The result: hundreds of wind‑tunnel components tested monthly, parts produced in hours rather than weeks, reduced cycle times and costs, an expanded aero capability (growing the department significantly) and an increasing number of printed/sintered components on the race car.

Lotus F1 Team

Nick Chester

Technical Director