3D Metal Printing

Creating new 3D functional, lightweight parts

Commercial challenge

Reducing the unsprung weight of upright struts is essential to the performance of any car—this is especially true for a solar racing vehicle. The lighter the components, the smoother and faster the car can run.

Students with the Sunswift group at UNSW had bionically designed front and rear struts for minimum weight and maximum strength. Now they needed an expert partner to help manufacture their designs. They turned to Raymax, as we previously installed a 3D metal printer for the engineering department.

Sunswift Racing prides itself on being on, or ahead of the technology curve. Our partnership with Raymax has given the team access to the very latest in generative manufacturing and that allowed some of our next generation engineering to turn their designs in to reality.

Professor Richard Hopkins – Sunswift Principal


When the team turned to us for manufacturing advice, we were delighted to sponsor them. The Raymax team contributed to the design, arranged the 3D metal printing of the car parts in collaboration with our partners, and funded the production of the samples.

The 3D metal printed car part—struts, as shown—are made out of aluminium. This metal is ideal for this application because of its light weight, ease of machining, and structural strength when bionically designed and optimised.

The struts have been adapted to the car, with the first shakedown run taking place in early 2022.


The COVID pandemic significantly delayed testing of the car’s performance and struts. Several races and the exhibition run scheduled for late 2021 were unfortunately cancelled. However, COVID permitting, the car will be run and tested in 2022. We look forward to being part of that process and will update you shortly on the results.

Why Raymax

We make laser light work for you. We’ve spent over 30 years demonstrating what’s possible with lasers. In doing so, we’ve helped modernise Australian and New Zealand industries. You’ll be working with a team of physicists and factory-trained engineers—leaders in the supply of laser solutions and photonics equipment. We’re experts in material interaction research. Wherever possible, you’ll be introduced to new technology that can improve operation in ways you might not have imagined possible.

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