F1 car parts that are to be wind tunnel tested are made by the process of stereolithography (SLA), a form of 3D printing at either 50% or 60% of the final car size.
The SLA is then coated in nickel by BJS to have the same rigidity as the full size carbon fibre parts that will be fitted to the actual race car.
BJS offers a cold nickel electroforming technique that conforms more closely to the SLA and doesn’t distort or stress the part. Generally 6 SLA’s are made of each parts, each with a very small difference are tested and the part that produces the best result is made in carbon fibre and fitted to the car for the next race.
Typically, nickel is deposited at either 100 microns or 150 microns thickness with the SLA part being printed with a matching offset. Standard turnaround time is 24 to 30 hours from receipt of pre-booked parts.