Case Study: McLaren Racing achieves faster development and 9,000 parts/year production with Stratasys Neo800 3D printing

McLaren Racing 3D printing to get the edge on and off track

McLaren Racing, competing in Formula One under tighter FIA design windows and budget caps, needed faster, cheaper ways to iterate aerodynamic and production parts while preserving high accuracy for embedded sensors. To meet that challenge the team turned to Stratasys and its Neo800 stereolithography 3D printers (using materials such as Somos PerFORM Reflect and Somos DMX SL-100) to bring more manufacture in‑house and compress development cycles.

Stratasys deployed a suite of five Neo800 printers and materials that produce large, high‑definition components and sacrificial tooling, enabling McLaren Racing to print up to 9,000 parts per year, turn a 60% scale top‑body around in 3–4 days, and cut post‑processing by more than 30%. The result is reduced subcontractor costs, faster iteration (about four car sets per component before the next revision), integrated sensor housings (50–60 pressure taps), and a much tighter, lower‑cost feedback loop for on‑ and off‑track performance development.

McLaren Racing

Tim Chapman

Head of Additive Manufacturing