Nicolas Lenzi Loeffler, 16, designed new front wing endplates for his Dallara F312 Formula 3 car, had the core printed in PETG with PrintTexx, and laminated it in carbon fiber. He ran the part at the Mugello race weekend. Only three fast laps were possible, so the effect on lap times is unknown.
How was the part designed and built?
The F312 runs the 2012 aero package, whose front wing endplates are nearly flat boards. Lenzi Loeffler took most of the new geometry from Dallara's 2026 F326 package, including its wave and wider profile, but skipped its triangular shape to stay closer to current Formula 1 styling. He modelled it in Onshape and checked pressure and airflow around the endplates with CFD.
The base structure was printed in PETG with help from Julian Schubert and Leander Goth of PrintTexx. Carbon fiber lamination then added stiffness and a race-ready finish.
What happened on track?
The parts were fitted just before the session, and he managed three fast laps. He reported that the front axle felt pushed harder onto the track and steering felt heavier and more direct. All parts survived, but with so little running he could not tell whether lap times improved.
What it means
The project is a motorsport case, not an industrial one, but the workflow transfers: a printed polymer core defines complex geometry cheaply, and a composite skin carries the load. For small manufacturers, the lesson is that low-cost CAD, CFD and FDM can shorten design iterations, while the missing lap-time data shows why validation still needs real testing before any claim of benefit.
Frequently asked questions
What material was the front wing core printed in?
The base structure was printed in PETG and then laminated with carbon fiber.
Did the new front wing improve lap times?
Unknown. He completed only three fast laps with the part, so no lap-time comparison was possible.