HALO system processing

The Halo system is a safety feature designed to protect Formula One drivers from fatal injury caused by rollover accidents. It consists of a titanium structure that sits above the car's cockpit, supported by a single vertical pylon and mounted to the car's survival cell and cockpit surround.

The main goal of this project is to select the material and design a factory process for manufacturing the Halo system using titanium alloy Ti 6Al-4V. The process includes pre-machining and welding, as well as load testing to ensure the Halo meets safety requirements. The electric bending machine is used to achieve a proportional bend, while a 5-axis milling machine is used to create the complex shape of the V transition.

While the Halo system was ultimately chosen by the FIA, alternative solutions such as the Aeroscreen and Shield were also considered.