Porsche Cup Scrutineer uses rapid CNC-machining service Firstcut

Over the years, Mr Magin has developed a range of test equipment and devices that fit into a travel case and can be easily transported to races. All his test products were produced using parts made by the rapid CNC-machining service Firstcut, from Proto Labs.

Mr Magin comes from a motor racing family, so racing is in his blood. Fairness and sportsmanship are close to his heart, because, he insists, it's only when the races are close that you can experience the true excitement of motorsport.

Mr Magin says: "A racing weekend costs a participant between €20-30k (16-25k). If the conditions in a race are not equal, the competition loses its attractiveness to competitors and also to spectators." Porsche is known for its strict controls for those competing in the Porsche Cup series, and Robert Magin's company, Romtec GmbH, in Walldorf, near Frankfurt, ensures the rules and regulations for racing cars are adhered to. Immediately after each race, all parameters are checked. He says: "A race car has more than 50 sensors recording data, which we can read. Furthermore, we check, for example, the correct size and shape of the spoilers; take measurements of the wheels and tyres, and take fuel samples."

Mr Magin has noticed over the past decade or so how thorough testing is increasingly demanded in all levels of motorsport. He notes: "Over time we have developed better and better testing methods and set many, new standards. The organisers appreciate this very much, since the enforcement of the regulations increases the attractiveness of the brand to all parties, and also demonstrates professionalism." Porsche currently has around 20, global brand "cups'. Currently, Romtec provides scrutineers for the Porsche Mobil1 Supercup and the Carrera Cup.

Portable testing devices

Mr Magin continues: "The manager of the various Porsche Cups came to me with the desire to pack all testing devices in a portable box, so that everything could be transported safely to the many venues during the international racing season. They asked me to design the equipment and specify a date when the box and its contents would be ready."

Mr Magin's first task was to find a CNC machine shop that could machine his aluminium calipers and templates. He knew one or two companies in his region, which did regular jobs for the motor racing sector. So, he approached them first. When they told him how long he would have to wait, he was disappointed.

He remembers: "Lead times of four months or more was the norm". He shopped around, but no one could make his parts in less than a few weeks. What's more: "All of them required 3D data in order to manufacture the parts I required. Now, I hadn't worked with CAD for over 25 years. But, I discovered free programs such as Autodesk 123D, so I set myself the task of creating the models. Since then, I have bought a full version of Autodesk Inventor and I've discovered I really enjoy the design phase."

To begin with, Mr Magin produced prototypes using a 3D printer. He says: "The parts were almost always useless because they were not regular in shape and sometimes I found - after as much as five hours of printing time - that the heat plate was slipping, for example." Frustrated by the waste of time, Mr Magin began looking on the Internet for alternatives, which is where he first discovered the rapid CNC machining service Firstcut, from Proto Labs.

He syas: "You cannot imagine how excited I was! One Thursday, I uploaded the 3D model and the following Monday, my finished parts, made using the production-intent material, arrived on the doorstep! The Proto Labs production facility is in England, which makes such a quick delivery time even more remarkable. But, what I really think is sensational, is the online quotation tool, FirstQuote. It lets me upload my 3D CAD model then, in just a matter of hours, I receive the quote including free design tips and suggestions directly related to my parts. If I change the quantity or the material of the parts, the new price will be displayed immediately - a truly unique service!"

In no time at all, Mr Magin had his first, complete box for presentation to Porsche. Called Scrutinator, the box provides space for a complete PC workstation and all calipers, test equipment and tools required to allow a scrutineer to carry out his work. He recalls: "The presentation was enormously successful. Ten of the 21 representatives of the Porsche Cups immediately placed orders, and more are likely to follow. I now produce all the parts with the Firstcut service from Proto Labs, because the quality is always 100 per cent and the service provides a huge amount of flexibility. The first box is now on its way to Australia, in time for the start of another, very exciting season."

To learn more about the rapid CNC-machining service Firstcut from Proto Labs, please visit www.firstcut.eu/gb.