Case Study: Sauber Group achieves rapid, high-throughput aerodynamic development with 3D Systems 3D printing solutions

Sauber Engineering Chooses 3D Systems to Power Constant Innovation

Sauber Motorsport’s engineering arm needed to accelerate relentless car and aerodynamic development for competitive Formula One performance. Faced with tight lead times and the need for rapid wind‑tunnel iteration—far faster than conventional carbon‑fiber production allows—Sauber required a high‑throughput, high‑quality production solution to support constant testing and improvement.

Sauber partnered with 3D Systems, deploying a 15‑machine in‑house additive factory using SLA (ProX® 800) and SLS technologies and Accura® materials to produce 100–150 part sets daily (80–90% SLA for wind‑tunnel models). The result: faster, more accurate aerodynamic cycles (dozens of iterations per program), cost‑effective low‑volume parts and tooling, and sustained productivity that fuels ongoing innovation and customer services across industries.

Sauber Group

Reto Trachsel

Head of Aero Design