pantherxxx wrote: ↑29 Jan 2026, 05:11
Keith Ferrell (Ford’s Additive Manufacturing Lead for Red Bull) confirmed that Ford is 3D printing "parts that cannot be made by traditional methods" (VoxelMatters, Feb 2025). These include cold plates for batteries and cooling plates for the internal combustion engine.
Unlike traditional radiators that need huge air scoops, Ford uses Direct Metal Laser Sintering (DMLS) to print plates with internal "galleries"—microscopic, curved channels that flow coolant with far higher efficiency.
Maybe these 3D-printed plates are so efficient at rejecting heat, and that's why RB22 can afford such narrow sidepods?
Ford Performance’s Christian Hertrich noted that these parts are tested with X-rays and CT scanners to ensure these "invisible" internal channels are perfect. By using their Advanced Manufacturing Center in Michigan, Ford reduced the time to manufacture these complex cooling components from 16 days down to just 5 (that's huge). On January 7, 2026, Ford Racing's powertrain chief, Christian Hertrich, confirmed they slashed manufacturing times from 16 days to 5 days.
As far as I know other teams like Mercedes and Ferrari use 3D printing mostly for rapid prototyping (plastic models for wind tunnels) or small, non-critical metal brackets.
While Ford is using it as a primary manufacturing tool for the core thermal architecture of the engine. Ford is currently the only manufacturer with the dedicated industrial 3D-printing labs (like the Advanced Manufacturing Center in Michigan).
That is a lot of "beads and mirrors" talk. Empty marketing BS.
All teams rely heavily on metal printing.
DMLS has now been the industry standard for, say, 20 years.
Checking internals with x-ray or tomography is standard quality control of any metal foundry of technical parts.
Speeding up the process is actually easy using multi-curtain and high power lasers. It just requires a lot of €€'s. And money has never been an issue in f1.