Ex-Core in Formula 1
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changing the game
While the veil of secrecy that surrounds Formula 1 development precludes EX-CORE® from naming its partners, use of Ex-Core carbon-fibre technology is growing in the pinnacle of motorsport.
At least three current Formula 1 teams are in engaged in development and validation programs with Ex-Core, largely for two reasons.
The first is the strength-to-weight ratio of Ex-Core, with the sandwich foam adding a level of bending and torsional strength unmatched by any other carbon-fibre production technology.
The second is the ability to create impossible angles in a one-shot mould process, and to do it quickly, even in hours, and even on-site at a racetrack, if necessary.
Unmatched Strength-To-Weight Ratio
Any load can be distributed more effectively and evenly across the component, compared to non-syntactic foam cores, giving Ex-Core components an inherently high shear strength.
This enhances the torsional and bending rigidity of Ex-Core components, giving greater overall strength and stiffness.
As a bonus, the even application of internal pressure in curing translates to an even spread of solidified foam in the finished component, reducing the resonance that usually accompanies stiff CFRP pieces.
Don't Wing It
Formula 1 teams have, so far, used EX-CORE® on wings for added strength without a weight penalty, but there are other areas where it can, and will, be applied.
For now, the ability to push carbon sheets against near zero-radius angles in moulds is being proven in wings, where they can be exposed to tremendous forces in Formula 1.
Front wings are also the bumper bars of Formula 1 cars, and area exposed to accidental collisions with other cars, or barriers, and teams are looking for a strength advantage here.
While less suitable for an entire chassis, Ex-Core’s range of depths means it can be deployed across many parts of the car and its bodywork, as well as its core engineering.
Race To Innovate
But Formula 1 development is about speed, which is also where the no-bureaucracy management structure of Ex-Core also comes in to play. Ex-Core can make fast decisions and implement new tooling or trial series very quickly, compared to the industry standard.
Given that Formula 1 now operates on a cost cap, it’s also an advantage for Ex-Core that its production costs are far cheaper than conventional CFRP production as well.
Contact Ex-Core to explore, in complete confidentiality, your carbon-fibre use case.