Formula racing is about speed both on the track and in the garage. With 14 F2 races annually, highly restricted testing opportunities, and strict car enhancement rules, teams have limited time to adjust during the season. Pre-season testing is limited to about six days, spread across two to three official test sessions, and in-season testing is almost non-existent. All teams use the same cars and engines in Formula 2, Formula 3, and Formula 4, making the driver’s skill and engineering ingenuity the key differentiators. This is why AIX Racing has integrated 3D printing into its operations.
3D printing is ever-present in AIX Racing’s workshop, from functional parts and prototypes to custom tools and jigs. For example, they’ve created a 3D-printed custom screwdriver with different-sized bolts on each side, tailored to a specific mechanic’s hand, saving precious seconds during pit stops. Another critical tool is a 3D-printed mounting part for a powerful cooler used to cool the engine between laps, or custom-designed battery holders for more powerful cells.
Precision and Adaptability Under Pressure
Under the hood, AIX Racing uses 3D-printed airflow tubes to guide cool air to specific car or engine parts, allowing rapid adaptation to race conditions. These parts would be complex and time-consuming to produce without 3D printing. In the car’s “safety zone” around the driver, where fire-proof materials are required, AIX uses self-extinguishing Prusament PETG V0 filament. Many 3D-printed parts are covered with tape imitating polished carbon fiber to protect proprietary designs.
AIX Racing relies on several Original Prusa MK4 3D printers for parts production and an Original Prusa XL for prototyping. They also take an Original Prusa MK3S+ to race tracks worldwide in an enclosure, enabling on-site production of replacement parts or adjustments overnight. PC-Blend Carbon Fiber is their go-to material for its heat resistance, durability, and stability, while Prusament PETG is used for simple prototypes, and Prusament Resin Model and Flex are used for models and flexible joints, respectively.
A 3D-printed custom screwdriver tailored for a mechanic.
A 3D-printed airflow tube for engine cooling.
SLA-printed custom end-caps.
Custom 3D-printed battery holder for enhanced performance.
Established by Paul Müller in late 2021, the PHM Racing team quickly made its mark in 2022 by competing in three Formula 4 Championships. A key step forward came when they acquired Formula 2 and Formula 3 licenses from Charouz Racing System. They partnered with AIX Investment Group to change to AIX Racing in 2024. The team also made history in FIA F3 as Sophia Flörsch became the first female driver to score points. With its clever use of technology and a practical approach to integrating 3D printing into its operations, AIX Racing is recognized as a very innovative team.
