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The 3D-printed Titanium Alloy Racing Safety Structure Successfully Saved The Lives of Racing Drivers

Views: 0     Author: Site Editor     Publish Time: 2025-06-26      Origin: Site

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In the recent Bommarito Motor Group 500 race, two cars collided at high speed.Among them, the Chevrolet racing car flew up and glided on the asphalt road with its bottom facing the sky, bursting out bursts of sparks.Related reports pointed out that the driver was not seriously injured, and most of the impact of the impact was absorbed by Aeroscreen.Aeroscreen is a 3D-printed cockpit safety device that was first launched in 2020 and upgraded in 2024 with a lighter design.

This device is a mandatory configuration for all NTT INDYCAR series road and street racing cars.It uses a 3D-printed titanium alloy frame, which is used with a laminated polycarbonate bulletproof windshield.Together, they form a protective barrier, and their function is similar to the Halo anti-collision protection system used by Formula One cars since 2018.

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Before its debut in 2020, several manufacturing technologies for Aeroscreen production have been explored.It is reported that the original design was cast from titanium alloy.However, due to the long production cycle, it could not be completed within the tight deadline before the 2020 INDYCAR season opener.Therefore, the team chose to use the EOS M400-4 laser powder bed melting (LPBF) 3D printer to manufacture the frame.

The original Aeroscreen (Version 1.0) used a frame welded from five 3D printed parts.In pre-race tests, it withstood the equivalent of 34,000 pounds of impact, while the bulletproof windshield withstood the impact of a 17.3-pound object traveling at a speed of 220 miles per hour.The device debuted in track testing at the Indianapolis Motor Speedway in October 2019 and was officially put into competition in February 2020.

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Version 2.0 was launched last year, a lighter windshield designed to improve performance and comfort.It integrates air vents to improve the cooling effect of the cockpit, and is equipped with 3D-printed front rubber to help prevent hand injuries in collisions.The upgraded version will debut at the Acura Grand Prix in Long Beach in 2024.Its weight was reduced from 18.9 pounds in Version 1.0 to 14.5 pounds, while maintaining the same strength as the original version.This is thanks to the new topology-optimized 3D-printed titanium alloy frame.

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The upgraded Aeroscreen is combined with a bulletproof windshield to reduce the total weight by 11.1 pounds and the downforce by about 35 pounds.

TinoBelli, director of aerodynamic development for the NTT INDYCAR series, said that enhanced cooling performance is essential to improve the performance of the car.She pointed out in the press release that drivers have always emphasized the importance of improving airflow, because their body temperature in the race usually exceeds 100°F (about 38°C).Racing teams can also install optional filters to prevent dust from entering the cockpit.


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