Pushing mechanical performance to the max, lightening components and revolutionising production: these are the objectives at the heart of the innovative project born in the Emilian Motorvalley, which features Gentilini Power Train, 3D4MEC and START 4.0, with the technological support of Boehler Voestalpine. The project was supported as part of the industrial research and innovation activities financed by START 4.0 through PNRR funds.
In the heart of Bologna, where the two SMEs involved are based, a challenge is taking shape that combines advanced engineering and additive manufacturing: a camshaft for racing engines has been created in special E185 steel, 14% lighter than the traditional version. A technical achievement considered exceptional by industry experts, not only for the geometric complexity of the component but also for the innovative nature of the material used.
The E185 alloy, developed specifically for extreme applications in Formula 1 and Oil & Gas, is optimized for production using L-PBF (Laser Powder Bed Fusion) technology, making it practically unusable with conventional bar machining. Thanks to 3D4MEC’s technical expertise, it was possible to industrialize the 3D printing process of these metal powders, opening up entirely new scenarios for the world of motor racing.
Additive manufacturing allows for total design freedom, reducing production waste by up to 90% compared to technologies such as turning and milling. The benefits in terms of logistics and operations are clear: lead times reduced by 30-40% and optimization of the supply chain with a drastic reduction in tied-up capital, replaced by ready-to-use powder containers for just-in-time production.
In light of the results achieved, Gentilini Power Train has strengthened its staff with new technical and commercial resources, applying to become the first operator to bring additive manufacturing in special steel to Moto GP. In parallel, a strategic acquisition has been launched in the automotive spare parts sector, with the aim of extending the application of these technologies to aftermarket production.
The project also has a demonstrative and strategic value, with a collaboration with an important national Motorsport player, and represents a concrete example of how digital transformation and manufacturing 4.0 can accelerate innovation in high-performance sectors.
With this project, START 4.0 confirms its role as a technological catalyst for the Italian industrial fabric, supporting solutions that combine research, sustainability and competitiveness.