Manufacturing 'Double Stanchion' Considering Athlete Physique and Position

Stratasys announced that the U.S. Luge National Team utilized Stratasys FDM (Fused Deposition Modeling) 3D printing technology at the 2018 PyeongChang Winter Olympics to manufacture and test competition sleds customized for individual athletes in a faster and more cost-effective manner.

The U.S. National Team utilized various high-performance materials from Stratasys when 3D printing key layup and sacrificial tool components used in carbon fiber composite sled manufacturing. The advanced FDM technology provided by Stratasys enables a level of personalization impossible with conventional composite processing methods, and such customization capabilities are considered an important success factor in the manufacturing of competition sleds that descend at speeds up to 87 mph (approximately 140 km/h).

The U.S. National Team utilized Stratasys ST-130 sacrificial tooling material in the manufacturing process of the 'double stanchion,' a component installed at the front of the racing sled that precisely positions and secures the athlete's legs during competition. The double stanchion must be manufactured considering the athlete's physique and position within the moving sled, requiring a high degree of complexity and geometric expertise. The U.S. National Team designers utilized water-soluble ST-130 sacrificial tooling material to 3D print and assemble the mandrel and layup, then dissolve away the tooling material, completing the entire process within one week.

Following the successful manufacturing of the double stanchion, the U.S. National Team applied 3D printing technology across all areas of racing sled manufacturing. Various techniques utilized in the prototype phase, including the use of detachable tooling that adjusts the length of the sled's mid-section according to each athlete's height, were equally applied to the manufacturing of sleds used in actual competition.

Jon Owen, Technical Program Manager for the U.S. Luge National Team, stated, "Luge is an extremely challenging sport where victory and defeat are determined by subtle differences within a fraction of a second. Our athletes are expected to achieve better results through sleds manufactured with consideration for comfort and aerodynamic aspects," and explained, "Through collaboration with Stratasys, our national team has become more competitive on the world stage by undergoing design modification and track testing processes that are significantly faster and more efficient than conventional methods. Additionally, through minimized manufacturing costs and time, we were able to manufacture sleds customized to each athlete's physique while balancing both sled comfort and functionality."

Scott Sevcik, Vice President of Manufacturing Solutions at Stratasys, explained, "Stratasys customers are transcending existing limitations in performance, efficiency, and reliability through rapid tooling, prototyping, and parts manufacturing provided by 3D printing technology. This collaboration with the U.S. Luge National Team is a representative example of how additive manufacturing technology satisfies the major requirements of specialized professional customers," and stated, "We are greatly honored to support the application of FDM technology to the U.S. National Team, recognized as the best team in winter sports, and to contribute to their achieving even better results."