A renowned sports car manufacturer has been transforming the design and production processes of its world-class supercar, the Mono R, by leveraging the power of the Ultimaker 3D printing ecosystem. BAC's adoption of this innovative technology has resulted in significant improvements in design iteration, cost reduction, and overall manufacturing efficiency.
BAC faced a challenge in producing small-batch bespoke parts for the Mono R. Traditional manufacturing methods like CNC machining or injection moulding was not a practical solution due to their limitations.
Seeking an alternative, BAC turned to the Ultimaker 3D printing ecosystem, which allowed it to produce highly customisable and high-quality parts in a fast and cost-effective manner.
Initially, BAC utilised 3D printing for rapid prototyping but soon realised the broader implications of this technology. BAC expanded its use of Ultimaker 3D printers, incorporating them into its production line to create more than 40 different end-use parts for the Mono R.
These parts included structural engine components, light surrounds, wing mirror arms, and engine runners, showcasing the design freedom and complex geometries made possible by 3D printing.
The adoption of the Ultimaker 3D printing ecosystem brought several key benefits to BAC:
- Fast and inexpensive production: BAC can produce highly customisable parts quickly and at a reduced cost;
- Supply chain optimisation: The Ultimaker Digital Factory facilitated efficient supply chain management, allowing BAC to manage and store digital files, printing parameters, and material specifications in a centralised hub. This ensured consistency and repeatability across multiple printing instances;
- Enhanced design flexibility: BAC can create intricate and complex geometries that were challenging or impossible to achieve with traditional manufacturing methods. This opened up new possibilities for customisation and personalisation;
- Accelerated design iteration: By utilising 3D printing, BAC can rapidly produce and test multiple design iterations, incorporating customer feedback and making refinements based on functional requirements. This iterative approach led to optimised parts in terms of performance, ergonomics, and aesthetics.
The Ultimaker Digital Factory further contributed to BAC’s success by providing centralised digital inventory management, design version control, print job replication, remote print monitoring, automated workflow integration, and data analysis and reporting. These features ensured repeatability, eliminated errors, and allowed for data-driven decision-making.
BAC also benefited from the Ultimaker Material Alliance Program, which offered a wide selection of industrial-grade materials specifically tested and optimised for the Ultimaker 3D printers.
BAC exclusively used Covestro materials, such as the carbon fibre-reinforced nylon Novamid CF10 filament, for critical parts requiring structural strength. The material profiles and print settings provided by the Material Alliance Program ensured consistent and high-quality results.
BAC acknowledges the pivotal role of local support and stated that it might have delayed adoption if it weren’t for the invaluable assistance it received.
“The local support we had has been instrumental in our seamless adoption of this technology," said the firm. "Inspire 3D is Ireland’s professional 3D printing systems provider. We help and encourage our customers to adopt additive manufacturing, offering training, applications development, consultancy, support and installation."
We are available for drop-ins and scheduled machine demonstrations. Just give us a call or drop us an email. Telephone: 040480069. Email: support@inspire3d.ie