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MCT Engineering: Pushing the Limits of Motorsport Manufacturing

with the FUNMAT PRO 610HT

For nearly three decades, UK-based MCT Engineering has been at the forefront of carbon-fiber manufacturing for hypercars and Formula 1. Their clients include some of the most prestigious automotive brands in the world.

The Challenge

To stay ahead in motorsport, MCT needed a faster, more flexible way to produce high-precision jigs, molds, and low-volume components that could withstand extreme temperatures. Traditional methods were costly, time-consuming, and sometimes unpredictable in maintaining tight tolerances.

So, how did MCT cut lead times from weeks to just hours, unlock new material capabilities, and boost production flexibility?

Discover how CDG 3D TECH and INTAMSYS  partnered with MCT to deliver a game-changing solution.

🔗 Read CDG's original article
🔗 Visit MCT Engineering

Download the Case Study
New Wheel Package

Enhanced aerodynamics and kinematics improve the car's handling and speed, crucial for better track performance.
Carbon Rim and New Brake Caliper
Lighter and more durable, these components ensure superior control and reliability, enhancing overall performance and safety.
Carbon Rim and New Brake Caliper
The E0711-11 EVO includes 99 3D-printed parts, reducing weight and production costs, showcasing the team's commitment to advanced manufacturing.
Weight Reduction
High-performance polymers and 3D printing have reduced the EVO's weight by over half a kilo, enhancing speed and agility on the track.

After thorough research and benchmarking, WEERG chose INTAMSYS as their supplier. The INTAMSYS FUNMAT PRO 410 met all their requirements with features like a heated chamber, dual heated nozzles, and a heated filament chamber.

INTAMSYS offered one single solution that got it all:

  • A robust printer with a sleek aesthetic finish, heated chamber, dual heated nozzles, and heated filament chamber.
  • Free and user-friendly software with incorporated printing settings (Click and Print experience) for a wide range of materials (from PA12-CF to PEEK).
  • Reliable support, and most importantly for WEERG, honesty and a true partnership.
WEERG also appreciated the user-friendly software with incorporated printing settings and the reliable support from INTAMSYS.

They went for INTAMSYS and received their FUNMAT PRO 610HT in June 2021. Since the purchase of the printer, they have printed many prototypes, some end-use parts, and from time to time jigs/fixtures and tooling parts.

As the printer has a high chamber temperature (up to 300°C), it also means that all temperatures in between are covered too. 4D Concepts has printed out parts of many plastic types; from PLA, ABS, PC, to PAEK, PEEK, PEI 9085/1010.

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4D-Concepts-0222-3-1024x938

4D Concepts – prototype of a temperature-resistant pulley made of glass-fiber reinforced PEEK (PEEK-GF).

 

We accompany our customers in a professional manner throughout the entire project - from planning and design to the prototype or the production of a complete series. Combining our 3D printing processes with conventional component processing, post-processing and surface refinement of the prototypes, small series or even a trade fair exhibit is our daily business. Since the company was founded in 1995, our experienced team in Gross-Gerau has made a name for itself well beyond the borders of the Rhine-Main area. We are one of the leading service providers for everything to do with 3D printing and have more than satisfied customers from a wide variety of industries - from the automotive and consumer goods industries to mechanical engineering and companies from the medical technology sector.

Alex Di Maglie
Managing Director,  4D Concepts

We were looking for printers that can print high-performance materials and run 24/7 on our production floor. INTAMSYS offered a robust printer, a nice aesthetic finish, and a true partnership.

Matteo
Founder & CEO, WEERG

The application of high-end filaments made of high-performance plastics such as PEI is not new to the field of 3D Printing. However, it requires both, a wide range of skills (materials and production) and the appropriate machinery.

Thanks to its large-format 3D printer from INTAMSYS, 4D Concepts can now process a wide range of high-end plastics with excellent thermal and mechanical properties for prototyping. Parts are out of PEI 9085.
 

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The INTAMSYS FUNMAT PRO 410 has been a performant and reliable tool since day one. It allows us to process high-performance polymers that enable our customers to innovate with them in highly loaded, thermally challenging, and metal replacement applications. It gives us the confidence that is needed to print 24/7 unattended with long print jobs of 100+ hours. It redefines what can be achieved with FDM technology.

Fabio Trotti
3D R&D Manager, WEERG

  • INTAMSYS FUNMAT PRO 410

    3D PRINTER

    FUNMAT PRO 410

  • 图片3

    COST-EFFECTIVE

    Print Larger, Print More

  • 4D-Concepts-0222-3-1024x938

    OPEN

    Open-Sourced Filaments

Greent team

Click DOWNLOAD to Get the Full Customer Story

Our Solution

INTAMSYS has sponsored the GreenTeam with a FUNMAT HT 3D printer, INTAM™ filaments, and consultation services. The 3D printed parts from INTAMSYS are used in various subsystems of the car, including the battery system, braking system, and power electronics.

  • intamsys-funmat-ht

    3D PRINTER

    FUNMAT HT

  • intamsys-funmat-ht-printing

    COST EFFICIENCY

    Lower Cost, Shorter Lead Times

  • materials

    MATERIAL SUPERIORITY

    Versatile INTAM™ Polymers

Tank Holder

The tank holder is a new part in this year´s racing car. The part is printed on the FUNMAT PRO 610HT with the material choice of ABS. For the driverless disciplines, the team uses pressurized air to activate the brakes in an emergency. This year, they changed the concept of how pressurized air is stored, which required a new mounting solution. The tank holder is designed to solve this challenge.

Tank holder
Flap Ribs (2)

Flap Ribs

Other 3D printed parts, using the FUNMAT PRO 610HT and PC material, are the flap ribs that play a crucial role in the construction of the car’s side wing. These ribs are glued into the carbon-fiber shells and incorporate threaded inserts for attaching the wing to the chassis.

While the team has used these ribs for years, they have redesigned for this season to accommodate changes in the aerodynamic shape of the wings. Using INTAMSUITE™ NEO and the 3D printing technology, they conducted topology optimization to achieve the lightest possible geometry, resulting in an organic shape that would not be possible to manufacture by milling.


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