Engineering

Formula One (F1) is arguably the World’s highest technology sport with over 30% of sales reinvested in Research and Development.  Performance in F1 is derived from a number of key first order performance drivers: engine, tyres and aerodynamics.  Development of these key performance drivers is made possible with composite structures and the flexibility they allow designers.  With composites making up over 80% by volume of an F1 car. Formtech Composites Mark Preston presented a paper recently at the CompositesUK 2010 Annual Conference. 

The paper analyses the reasons why they are used so extensively.  These reasons are primarily related to the rapid development cycles that deliver innovation, the methods that are used to mitigate risk that allow engineers to deliver designs that operate close to the limits of composite materials and the understanding of how integration of functions delivers innovation that is not always clear in the initial stages of a project.

While cost may initially inhibit the transfer of techniques and innovations, part of the technology transfer process will follow the reduction of complexity and the automation of the manufacturing value chain.  Integration of components, structural health monitoring and experimental techniques for certifying composites will increase the confidence of industries to push the usage of composites further than before, with targets for weight saving in the order of 50%.

Formtech Composites can offer stress analysis, NDT and other bespoke research and development services.

As the image above shows, Formtech has experience in crash testing, structural design and the development of serial production processes for motorsports, aerospace and high-end automotive.

Formtech has also begun supporting a number of projects in marine energy and electric vehicles. Carbon fibre composites have advantages in several areas, most commonly displayed using a specific stiffness presentation. 

Acoustic Emission - NDT

A core part of Formtech's development knowledge is contained in the unique acoustic emissions NDT technique developed in Formula One. 

Crash Testing

One of the useful aspects of carbon fibre is its highly efficient energy absorption characteristics.  In our case studies section of the website we have an example of the analysis, design and manufacture of a typical Formula One nosebox including information about our methodology and the analysis and then subsequent design of the layup involved.

Formtech Composites can provide bespoke services for the design and manufacture of prototypes and production of such high tech solutions.