Release Date: 
Tuesday, July 22, 2014 - 13:45
Media File: 

A Leg that Fits: Making Natasha's 3D-Printed Prosthetic in Two Weeks

Metal Technology (MTI) forges new path with metal 3D printing and English Racing

3d printer metal oil pump gear proX 300Albany, Oregon, has been a hotbed of metallurgical distinction since 1943 when President Franklin D. Roosevelt announced that the U.S. Bureau of Mines had selected the site to begin researching methods to create zirconium and titanium alloys. That decision provided the impetus for a thriving industry built on developing alloy systems designed to meet extreme applications.



High-performance sports cars require special care and a skilled technician to ensure that all their critical components are reaching their maximum potential. To take full advantage of each system’s capabilities, most racing vehicles also incorporate a series of customized parts that stretch performance. English Racing, a group passionate about tuning and racing cars, wanted to use such custom parts to push the boundaries of what’s possible for a Mitsubishi Evo. 

English Racing was having trouble at high RPMs (revolutions per minute), as the Evo was exceeding tolerable oil pressure limits and causing significant damage to the car’s engine. After several engines were destroyed, English Racing designed an innovative new pulley that had a larger diameter, which would cause it to turn slower and thereby lower the oil pressure. Though the solution was theoretically sound, the issue of manufacturing their part at low quantities for testing posed a problem. With traditional casting processes, part production would have been both time-consuming and costly, so English Racing searched for an alternative.

By working with Metal Technology Inc. (MTI), English Racing was able to 3D print their pulley on a ProX 300 direct metal printer bye 3DS in 17-4 PH Stainless Steel. Using this method, creating the final part only took 5 hours, and the Evo was on the track and testing three days later. A few months after their test print, the English Racing team ran the Evo at the Pikes Peak ½ mile top-speed event and placed first in the Sedan Class, reaching 184.9 miles per hour.

For more insight on direct metal printing, hear from the technicians and engineers of English Racing and MTI in the video below. To explore the subject in greater depth, register for our joint webinar with MTI, English Racing and 3DS, scheduled for Tuesday July 22, 2014, at 11:00 AM EST.

3D Systems Announces Latest Webinar on Direct Metal Printing

ROCK HILL, South Carolina, July 17, 2014 3D Systems (NYSE:DDD) announced today a new webinar titled:

3D Printing the Mystery of the Brain

The human brain—an organ that, despite ever-advancing technology to scan and understand it, still remains very much a mystery to researchers and scientists. But that technology is allowing those researchers to advance the understanding more quickly, and it forms the basis of the Philadelphia-based Franklin Institute's new exhibit, Your Brain.


Rapid Manufacturing Leader at Sahara Force India, Patrick Hawtin, plays a crucial part in the process that delivers upgrades to Formula One cars. With the help of 3D Systems’ stereolithography machines, he helps by turning ideas into parts that are then tested in the team’s wind tunnel.

In essence, what does your position entail?

My position has its challenges, as our department is responsible for scheduling and manufacturing hundreds of components for aerodynamic testing each week. We also manufacture components for the race car and various Research and Development projects - so there is usually a lot going on!

What we do is use 3D Systems' stereolithography machines, which effectively are very big and very accurate 3D printers, to create the parts for the wind tunnel models. This allows our aerodynamicists to test in real life what their calculations predicted.

What are the main challenges of your work?

The production deadlines are always tight, and in order to meet them the department operates around the clock, except on summer shutdown. We respond to demands from other areas of the team, so the day doesn't follow a structured schedule: I have to work to the job, and this means also regular evenings and weekends. They say you can never sleep in Formula One and sometimes that's exactly the case! The good thing is that we've got a good team with two other Rapid Prototyping Engineers on hand to help. With our fleet of rapid prototyping machines from 3D Systems everything gets taken care of quickly and easily.

How long have you been a member of the Sahara Force India Family?

I joined Force India in December 2007 and I have to say that time has flown by! This team is very much a family and whilst we are steadily growing, we are still relatively small compared to the teams around us. You get to know everybody by name which is nice and I think it enables us to be more dynamic - I hope that never changes.

Have you always been passionate about Formula One? How did you end up working in the sport?

Like so many of my colleagues, I grew up watching F1 with my Dad. I also have an uncle that works for one of our rivals, so it is fair to say the sport has always been in the family!

I started life as a Mechanical Engineering Apprentice and during that time I completed my HNC (Higher National Certificate) in Mechanical Engineering and specialized in Stress Analysis and Dynamics. Soon after that, I joined 3D Systems as a Field Service Engineer. I worked on additive manufacturing machines in every industry you can imagine and did a lot of travelling - UK, Europe and America.

Once my children started coming along, my wife told me I needed to knock the travelling on the head and it was at this point I was lucky enough to arrive here at Force India as an SLA Technician. Here has been home since!

What is your favorite Sahara Force India moment?

My favorite single moment has to be our team’s Belgian Grand Prix pole position and subsequent podium finish in 2009. That weekend really got people's attention and put the team on the map. It was the start of the progress that we have been continuing ever since.

And the most challenging part of your work?

The most challenging part of my work is reacting to any last-minute request that may come when the department is already running at full capacity. Deadlines are very tight and every minute is essential, and sometimes this requires a review of the whole production schedule. By liaising with the aerodynamicists, designers and the model shop, we look at where we can fit additional projects and what elements can be rescheduled. Once this is done, we still have to wait for the components to be issued, program them, prepare the build files and then start the builds on the 3D Systems' machines.

And what about the Paddy away from work?

I am always busy at home, I have 3 children under 8-years-old and they find the best ways to keep you busy! I do make a little time for myself though as I do karate once a week. My wife has an addiction to holidays too; to give you an idea, we currently have Croatia, France (skiing), camping in Wales and New York all booked for before the end of 2014. I will get her some counseling!



President Obama took part in Wednesday’s National Day of Making in more ways than one. As part of the Smithsonian X 3D program, the Smithsonian presented the first-ever 3D printed presidential portraits at the White House Maker Faire on June 18th. The portraits were created using two types of 3D scanners to give an accurate 3D model of our 44th President, Mr. Barack Obama. The display included a bust and life mask of the President, each printed using 3D Systems’ SLS technology, great for high precision facial detail.

The scan data, bust, and life mask will be displayed in the National Portrait Gallery as part of the Smithsonian’s collection of presidential representations. Other interesting scans and printable models, including a life mask of President Lincoln, can be found on the Smithsonian X 3D website.

How did you get involved with the National Day of Making?

president obama's 3D printed bust by 3D Systems

Release Date: 
Wednesday, June 18, 2014 - 09:45
Media File: 

The Future of Customized Fab-Grade 3D Printing

Release Date: 
Tuesday, June 10, 2014 - 14:30
DMN newswire


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