How 3D Laser Scanning Makes Formula 1 Racing Safer from Start to Finish Line

If one were to engage in a game of word association, chances are when you hear the phrase “Formula 1,” responses will be those associated with speed: racecar, acceleration, fast, momentum, velocity, etc.

But as much as Formula 1 is about speed, it’s also about controlling and channeling that speed with technology. Specifically, braking; the ability to slow a vehicle at critical moments to ensure driver safety and vehicle integrity.

The science of Formula 1 braking is extreme. It employs a technique known as brake cooling, a process which utilizes complex carbon fiber ducts to channel high-pressure air directly to carbon discs and calipers, managing temperatures that can exceed 1,200°C (2,192ﹾF). These systems, which also serve critical aerodynamic functions by managing turbulent air around the wheel, prevent brake fluid from boiling and enable optimal friction material performance.

Making sure drivers (and their vehicles) survive their trips around the track, working tirelessly in the background, is the talented team at Bräutigam GmbH and their use of advanced 3D laser scanning tech, the HandySCAN 3D.

The Fastrack to Precision Performance

Bräutigam GmbH is a highly specialized engineering company focused on the development and manufacturing of advanced fiber-reinforced composite (CFRP) components. Serving industries where precision and performance are critical, including the above-mentioned motorsport, along with general automotive, and aerospace, Bräutigam has built a strong reputation for delivering complex, high-quality solutions.

Headquartered in Freiberg am Neckar, Germany, and founded in 2016, the company prides itself on its end-to-end capabilities, managing the entire production process under one roof, from initial concept and design to final manufacturing and quality assurance.

With deep expertise in composite technologies, Bräutigam regularly contributes to technically demanding applications where even the smallest detail can have a significant impact on performance. It’s a firm where engineering knowledge and cutting-edge tools to ensure accuracy and reliability at every stage go hand in hand.

A Closer Look at Composites

Recently, as Bräutigam scaled its decade-long operations, limitations in its existing metrology processes began to surface. The company typically works with aluminum tooling and carbon fiber components (lightweight materials consisting of high-strength, low thermal expansion, carbon filaments embedded in a polymer epoxy, up to 10x stronger and 5x lighter than steel) both of which feature reflective surfaces that complicate scanning preparation.

Preparation required extensive surface treatment, including scanning spray and adhesive targets, significantly increasing setup time before measurements could even begin. Smaller features, such as threaded holes, could not be reliably captured with their legacy system.

The urgency of these challenges became even more apparent during a major undertaking: the scanning of more than 250 aluminum tools within a compressed timeframe. With limited quality control capacity, the combined burden of preparation and measurement risked creating a critical bottleneck.

Without intervention, production timelines (and ultimately customer commitments) were at risk.

Accuracy and Portability Delivered

Recognizing the need for a more efficient and scalable solution, Bräutigam evaluated modern 3D metrology technologies with several criteria in mind including, the use of non-adhesive targets, high measurement speed, and reliable technical support.

On each point, the HandySCAN 3D System delivered. Known for its accuracy, portability, and reduced need for surface preparation, the system offered a compelling combination of usability and speed.

The implementation process was seamless. With prior experience using FARO CREAFORM systems, the team quickly integrated the new scanner into its workflow. Within a week of delivery, operators felt confident handling the equipment, and full operational proficiency was achieved shortly after formal training.

One of the most notable applications of the HandySCAN 3D System involved the above-mentioned development of a Formula 1 brake cooling system.

The complex assembly consisted of approximately 50 individual components per wheel, each requiring precise alignment and dimensional accuracy. Bräutigam manufactured these parts using multi-part aluminum molds in combination with soft iron cores, forming high-performance CFRP structures.

Given the tight tolerances and aerodynamic sensitivity of the system, accurate measurement was essential throughout the production cycle. In its capacity as a trusted and highly versatile handheld solution, HandySCAN 3D enabled rapid, high-resolution data capture directly within the manufacturing environment, allowing engineers to verify geometries and identify deviations early in the process.

Racing to the Finish Line

As anticipated, the upgrade to the HandySCAN 3D scanner delivered immediate and tangible benefits across multiple dimensions.

• Dramatic Reduction in Preparation Time:The near elimination of scanning spray significantly reduced setup time. Non-adhesive targets further streamlined the process, minimizing pre-scan preparation and post-processing cleanup.
• Increased Measurement Speed:With an improved field of view and faster acquisition rates compared to earlier models, the system enabled rapid scanning of complex geometries, accelerating inspection cycles.
• Enhanced Workflow Efficiency:Reduced manual intervention allowed quality control teams to handle higher volumes without additional resources. The risk of bottlenecks during large-scale projects was effectively mitigated.
• Improved Data Quality and Reliability:Accurate capture of fine details, including small threads, enhanced overall inspection fidelity, supporting better decision-making and product quality.

“Beyond immediate productivity gains, the adoption of advanced 3D metrology reshaped our entire operational model, the portability of the HandySCAN 3D allowed it to function as a mobile measurement solution, enabling flexibly across different locations without the constraints of fixed installations.”
-Ralf Schuster, Bräutigam ‘s Operations Manager.

This adaptability proved especially valuable in dynamic production environments, where speed and responsiveness are critical.

A ‘Formula’ for Success

For Bräutigam GmbH, the integration of the HandySCAN 3D System represents more than a technological upgrade. It’s a strategic growth enabler, maximized through efficiency and precision. Not only for the motorsport industry at large and Formula 1, but for the diverse range of industries Bräutigam represents.

By addressing long-standing challenges in preparation time and measurement capability, the company has unlocked new levels of productivity while maintaining the high standards required in elite engineering sectors.

As demand for advanced composite components continues to increase, Bräutigam is well-positioned to meet future challenges head-on; equipped with the tools, expertise, and confidence to deliver superior results at scale.

“We have relied on FARO CREAFORM systems since the company was founded, and we have consistently had only positive experiences from inquiry to usage to support, we have never had a case where a delivery was delayed because the HandySCAN did not work. Our customers have also responded positively to the use of FARO CREAFORM solutions.”
-Mr. Schuster .

“I’m confident we will continue to measure as many CFRP components and tools as possible.”

And for Formula 1 and its advanced braking systems, the future of precision performance – and safety – seems bright.