As the motorsport world is changing fast, new demands on performance, materials and production technologies are set
  • The motorsport world is changing fast
  • Increasing demand of performance differentiators like the power unit, aerodynamics and suspension
  • New materials and production technologies: Potential for new aerodynamic designs and reduced fuel consumptions
  • Increasing demand for CO2 reduction will create a subsequent demand for alternative drives and lightweight materials

Ready to win the race!

Winning the race without compromises - with highspeed and full flexibility in design - by relying on the proven additive manufacturing processes at GF. With the AMotion Center, you benefit from uniquely combined competences under one roof. 

Our additive manufacturing process at GF is based on many years of experience with customers from various industries. Motorsport applications were among the first additive manufacturing projects we ever had and since then, we are absolutely passionate about it. Through our experience, the needs and challenges of motorsports engineers are not new to us - and we are ready to win the race together.

Setting new trends for the automotive industry

Speed is crucial in motorsports, not only on the race track, but also in product development and in adapting to latest engineering trends. Let us keep up with the pace to be ready for the next race together!  We offer rapid prototyping, spare parts on demand and short lead times and support you from the very first design concept. We know the latest trends and are ready for changes and challenges when you are!

3D-printing process

New dimensions

The bigger GF Casting Solutions 3D-printed demonstrator: 445 x 264 x 283 mm
The smaller GF Casting Solutions 3D-printed demonstrator: 225 x 165 x 167 mm
Material

Inconel 718

Density

8.2 g/cm3

Weight

19.5 kg/ 2.83 kg

Volume

2373.5 cm3/ 360 cm3

Additive manufacturing with GF

Consulting & development services

We team up with you! We offer full R&D Service, including material, process and design development; and excellent project management. We consult and support during the set-up of specifications.

Cost efficient all-in-one solution

Winning the race without compromises! We offer all post-processes in-house, we work time efficiently with one touchpoint in communication and we combine more than 50 years experience in casting and additive manufacturing in high-end parts. Our transparent and reliable services and cost structures allow you to fully focus on the race ahead.

We accelerate your time-to-market

Need to speed up your manufacturing processes? Benefit from fast turnaround time and a single point of contact: From the concept to the serial production. Our processes are independent from third parties: All processes from development to finishing take place under one roof.

Big parts or high quantity

Part size or quantity - We think big! In our 500 x 500 x 500 mm printing space, big and heavy parts are possible as well as small parts in big volumes (part quantity in one print job).

Best choice of technology

Finding the best solution! We make objective & reliable technical decisions regarding manufacturing technology (additive manufacturing vs. casting) and experience in customer applications, processes and production costs. Both technologies and all post-processing steps happen under one roof.

Fully certified value chain

Quality you can rely on! All our additive manufacturing and follow-up processes are certified according to EN 9100 and Nadcap. Our trained and experienced teams take care of the highest standards and quality management.

Our offer

We are ready to realize your 3D-printing challenge!

We offer the full additive manufacturing process as well as certified post processing in-house: including surface treatment, heat treatment and non-destructive testing. Our transparent and reliable services and cost structures allow you to fully focus on the race ahead.

In the following, we describe the key players and technologies behind optimized motorsport solutions like the 3D-printed GF demonstrator. 

Click on the + to learn more:

Rapid part production & spare parts on demand
We can produce th exact amount of required parts and deliver them within a few days or weeks
  • Delivery of parts within a few weeks/days
  • Order directly on demand
  • Test different designs at the same time without additional cost
  • Production of exact amount of required parts is possible
  • Reduced leadtime and cost
  • Fast turn around time
  • 1:1 copy of your part (even if not produced anymore)
  • Digital warehouse
  • No storage or tooling costs
  • Reduced risk thanks to in-house post-processes 
In-house development and validation expertise
Our central R&D team can set up and optimize your solution - for additive manufacturing as well as for casting processes
  • Characterization of material properties
  • Support and consulting in the product development process
  • Additive manufacturing oriented and compliant designs
  • Integration of additional functions and neighbor parts
  • Topology optimization and FEM simulation
  • Static and dynamic validation of components also under thermal boundary conditions
  • Leakage testing
  • Metallurgical analysis of components 
High design freedom
  • Strong focus on the part functionality
  • Better design possibilities even compared to casting
  • Extreme shapes:
    ‒ Hollow structures
    ‒ Unique double-wall construction design
    ‒ Very thin walls <1mm
  • Very complex shapes from thick to thin in one part
  • Topological optimization and possibility to integrate lattice structure: extreme weight and material reduction
Complex and extreme shapes from thick to thin in one part
Higher level of performance
Increased air flow, reduced weight and thermal insulation are possible thanks to the additive manufacturing process
  • Increased air flow through the cylinders’ combustion chamber augments the engine power output
  • Reduced weight of the usually heavy doubled walls - while achieving the thermal insulation required for optimal performance thanks to an air gap (not feasible with traditional casting methods)
  • Effective operation of the turbocharger thanks to increased thermal insulation
  • Cost advantage: not only within the geometry and performance of the application but cost savings through the reduction of process steps such as machining
High functional integration
With product development and process expertise, we can integrate multiple single parts into one design

Functional integration through product development and process know-how:

  • Integrating three single parts into one design
  • Reduction of welding to attach double-walled heat shield for joint/assembly activities and process steps e.g. tooling and or machining processes
  • Increased overall reliability of the turbocharger due to single-piece production
  • Reduced leakage risk at the interface between the different parts
Material properties
The tensile strength of additive manufacturing material is higher and the microstructure is finer than casting
  • Density: almost no inner porosities (in additive manufacturing evenly >99.5; in casting strongly influenced by the part geometry)
  • Additive manufacturing could avoid HIP-treatment (cost intensive process step)
  • Microstructure is finer than with casting: the tensile strength of additive manufacturing material is higher
  • High repeatability in additive manufacturing 
High freedom in surface geometry & design
Maximal design freedom thanks to additive manufacturing
  • Cost reduction as mating surfaces no longer need to be machined to tight tolerances
  • Reduced lead time compared to functional surface creation via casting
  • Cost-neutral feature
  • Possibility to create closed cavities without the need of molding or post-processing

Additive manufacturing process steps

Print job preparation

With state-of-the-art tools and proven expertise, our additive manufacturing team takes care of the print job preparation to make sure that the process can run properly. 

Preparing the printer

We provide the printer with the right powder, clean the optic lenses and take care of the machine calibration.

Print job

The laser is directly melting the component layer by layer. The remaining powder can be reused after a dedicated sieving process.

Depowdering (automated)

Once the print job is completed, powder and component are separated automatically and individually. 

Additive manufacturing at our AMotion Center in Stabio (Switzerland)

Post processes

Our post processing capabilities

  • Vacuum & cryogenic heat treatment
  • NDT inspection 
    (including analog & digital RX, LPI lines, 3D measurement, Zeiss equipment, GOM – Atos measurements syst. and electronic gauges)
  • Welding
  • Airflow test
  • Installation for chemical etching
  • Surface superfinishing processes
  • Finishing and polishing (more than 50 years of experience)
  • HIP**
  • Computer tomography**
  • Machining for semi-finished and finished components**

** not in-house

In our plants in Romania and Switzerland, we offer fully certified post processes for cast and 3D-printed components

Find the right technology for your project

Concept

To start with a concept, we always discuss about cost efficiency, a component's lifetime, number of parts, geometry and part size.

Precision casting

Depending on your project, precision casting might be the right choice. Benefit from 58 alloys and a certified value chain!

Additive manufacturing

Benefit from breathtaking speed and flexibility of the additive manufacturing process. With an expert team and certification, we develop and support your 3D-printing project.

Solution

What matters most is the accuracy of your solution and the fit to your needs. GF is your partner for casting and additive manufacturing and helps you decide on the right technology. 

Get in touch with us to join forces and win the race with full-speed additive manufacturing!

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Your Contact

Marco Salvisberg

Business Development Manager

GF Additive Novazzano SA

Via Gaggiolo 27

6855 Stabio

Switzerland

Relevant topics

Additive manufacturing

Additive manufacturing (AM) offers unlimited possibilities in terms of design, speed and production processes. We have the know-how to apply it in serial production.

Precision casting

Industrial manufacturing technology based on the so called lost-wax process used in the aerospace and energy industry to produce turbine blades and structural parts with complex shapes and cooling systems.

Research and Development

With the central Research and Development team, GF Casting Solutions provides an outstanding know-how and experience in lightweight design and process optimization for highly complex castings.