Stereolithography, accurate to a hundredth of a millimetre

3D printing dates back to the 1980s. Stereolithography (SLA) is the original method that is still in practice today. Photosensitive liquid synthetic resins are hardened layer by layer in the 3D printer by the UV component of the laser light. Stereolithography enables the highest accuracy thanks to its high resolution. Complex and self-supporting shapes require support structures: mounts and supports that are removed in an additional step after the printing process.
Stereolithography is mainly used for the aerodynamic development of our Formula One car in the wind tunnel. We also manufacture a wide variety of laminating moulds and cores, and we produce complex serial parts.

Selective laser sintering – fast, light, strong

The carbon-reinforced polyamide HiPAC is a proprietary development by Sauber Engineering. The powder-based material is melted in layers by selective laser sintering (SLS). The SLS process does not require support structures. It is used when particularly light and rigid components are required – from Formula One brake ventilation and body components for pre-production vehicles and prototypes to a wide range of ready-to-use construction elements.

Win-win cooperation

Our partner in the areas of SLA and SLS printing is 3D Systems, with whom we have been working closely for over ten years. In this constellation, we are also involved in the continuous development of processes and equipment, some of which we have adapted and modified to our specific needs.

Material overview and 3D plastic printing dimensions
(Material properties is reference only, actual properties depend on build settings)

Parameter HiPAC (SLS) Bluestone (SLA) HPC (SLA) Xtreme (SLA)
Density sintered at 25°C approx. 1,2g/cm³
Density solid at 25°C 1.78g/cm³ 1.61g/cm³ 1.19g/cm³
E module bending 7327MPa 8300 - 9800 MPa 9000-9700MPa 1520 - 2070MPa
Flexural strength 132MPa 124 - 154 MPa 137-157 MPa 52 - 71 MPa
E module tensile force 8304MPa 7600 - 11700MPa 8700-12000MPa 1790 - 1980 MPa
Tensile strength 85MPa 66 - 68 MPa 66-89MPa 38 - 44MPa
Crack expansion 2.7% 1.4 - 2.4 % 0.8-1.9% 14-22%
Melting point 172-176 °C
Heat resistance ca. 170°C 54°C
Glass transition temp. 71 - 83 °C 62-73°C
Build Size 500 x 500 x 750 mm³
500 x 500 x 440 mm³
650 x 750 x 480 mm³ 650 x 750 x 480 mm³ 650 x 750 x 480 mm³