Case Study: Sahara Force India F1™ Team achieves rapid development and high-precision wind-tunnel iteration with 3D Systems' SLA printing

Sahara Force India F1™ Team Crosses The Finish Lines With 3D Systems’ SLA 3D Printing

Sahara Force India F1™, based in Silverstone and Brackley, faces the relentless challenge of constantly re-optimizing its car between races. Traditional tooling and composite workflows took 5–7 days per testable design and couldn’t scale to the 20+ iterations needed for effective wind-tunnel development, slowing progress and increasing cost.

By bringing 3D Systems’ Stereolithography (SLA) in-house and using Accura materials, the team can produce hundreds of accurate, high-resolution parts per week (to within 0.1 mm) with smooth surfaces and temperature resistance for molds. This cut lead times and costs, enabled far more iterative testing and sensitivity in aerodynamic development, and sustained a development pace that would be nearly impossible with conventional methods.