3D Printing the Future of F1 Racing: Insights from Stefan Seidel, CTO of Pankl Racing Systems

APRIL 08, 2025 | Reading time: 5 min

 

In a riveting episode of the Additive Snack Podcast, host Fabian Alefeld engages with Stefan Seidel, the Chief Technology Officer of Pankl Racing Systems, to delve into the transformative role of additive manufacturing (AM) in the high-stakes world of motor racing.

This conversation highlighted how Pankl, renowned for its pioneering work in the aerospace and high-performance sectors, is leveraging cutting-edge manufacturing methodologies to redefine motorsports engineering.

 

From Austria to the Fast Lane of Innovation

Stefan Seidel, hailing from Austria, shares that Pankl's journey into AM began over a decade ago. Founded in 1985 by Gerold Pankl, the company initially made its mark with titanium connecting rods, setting the stage for its evolution into a leading supplier across motorsport, aerospace, and high-performance industries.

Austria's rich engineering heritage is underscored by Pankl's innovation-driven culture, which aims to influence global markets through excellence in manufacturing. Pankl’s unique offering, covering everything from R&D and design to simulation and material testing, puts it in a position to act as a system partner for major players in motorsports.

Revolutionizing Motorsport Manufacturing

Pankl's commitment to AM stands as a testament to its innovative spirit. Through partnerships with leading firms like EOS, they have integrated emerging technologies to craft components critical to racing success.

This includes elements such as the roll hoop, pivotal for both safety and performance, often manufactured in titanium due to its formidable properties and effect on the cars’ center of gravity. Other examples include winglets and aerodynamic devices, which keep changing with design iterations, along with hydraulic components and engine parts.

It’s clear that AM has become instrumental in Pankl's operations, particularly as motorsport demands escalate for lightweight, reliable parts. Advances in weight reduction technology and enhanced performance standards have proven the value of these advanced manufacturing techniques.

Pankl footrest stacked on EOS M 400-4 building platform

A Systematic Approach to Additive Manufacturing

Pankl's strategy encompasses a comprehensive approach to the production process, from raw material to final product:

  • Partnership With EOS and BÖHLER: Collaborating closely with these industry leaders ensures the consistency and quality of powders. EOS's cutting-edge machines, such as the M 400 series, play a key role in realizing complex structures, while BÖHLER's materials expertise enriches the potential applications further.
  •  Cutting-Edge Machinery and Processes: Technologies like Hot Isostatic Pressing (HIP) are implemented to enhance fatigue properties and ensure component reliability. HIP eliminates micro-structural voids within titanium components, elevating their performance in high-stress environments.
  • Optical Tomography (OT) Monitoring: This revolutionary in-situ process evaluation tool allows for precise control over the manufacturing process, ensuring that each component meets rigorous performance and safety standards before reaching the customer. OT monitoring provides a comprehensive snapshot of each component's "DNA," facilitating immediate verification of integrity and quality.

Cross-Industry Influence and Broader Applications

While rooted in the fast-paced world of racing, Pankl has expanded its innovative solutions across various sectors. The principles honed in competitive environments find applications in high-performance vehicles and aerospace — industries characterized by demanding standards and a need for precision engineering.

According to Seidel, Pankl's dedication is about integrating the right technology for each challenge. In hypercars, where component cost is a secondary concern compared to performance, Pankl's solutions highlight the crossover potential of motorsport technology. There’s a clear pathway from racing prototypes to applications in aerospace, where Pankl tailors their approach to meet stringent aviation standards, thereby replicating motorsport's drive for innovation.

Pankl footrest built support-free using EOS Titanium Ti64

Building the Future: Talent and Partnerships

A significant component of Pankl's success lies in its resolute focus on talent development and strategic partnerships. Education initiatives such as the Pankl Academy nurture a steady stream of skilled professionals versed in the latest manufacturing technologies. Collaboration with universities and industry partners further bolsters Pankl's capability to innovate and lead.

Seidel emphasizes that leveraging education and training ensures that the workforce is equipped to handle the sophisticated tech breakthroughs that define Pankl's operations.

 

Ensuring Quality in High-Stress Environments

As Seidel explains, Pankl's robust quality assurance processes are a cornerstone of its production methodology. Initial simulations of thermal and mechanical stresses ensure precision even before printing begins. After production, components undergo rigorous validation. Geometrical accuracies are verified with Coordinate Measuring Machines (CMM), and weld integrity is assured through expertise in modern machining techniques.

 

Looking Ahead: Pankl's Vision for Additive Manufacturing

As motorsports evolve, particularly with anticipated regulatory changes in Formula One by 2026, Pankl is poised to meet emerging demands for innovation in lightweight and high-performance components.

Seidel expresses optimism about Pankl's role in ushering in a new era of manufacturing where trust in additive processes will become ubiquitous across safety-critical and high-stress applications. 2026 is seen as a pivotal milestone, with whole new chassis and engine regulations expected to set unprecedented challenges that Pankl is prepared to tackle using additive solutions.

 

Conclusion

Stefan Seidel's insights on the Additive Snack Podcast underscored the transformative potential of AM in motorsport and beyond. By balancing innovation with strategic industry partnerships and advancing technical capabilities, Pankl Racing Systems continues to pave the way for excellence in manufacturing.

They not only solidify their status as a leader in engineering innovation but also set a standard that other industries striving for similar precision and performance can aspire to. For those interested in the detailed technicalities and future directions of Pankl's methodologies, this episode is a must-listen, offering a unique window into the company's pioneering strategies and impacts on the engineering landscape.