Formula Student Event
In the fast lane with SLS 3D printing
The SAE Racing Team at Munich University of Applied Sciences designs and manufactures its own racing car every year as part of the Formula Student racing series and uses 3D printing, among other things. Niklas Rösler and his team also took part in the largest Formula Student event at the Hockenheimring.
The interdisciplinary munichmotorsport team is made up of around 40 students from various faculties and disciplines at Munich University of Applied Sciences. From automotive engineering, electrical engineering and mechanical engineering to business administration, design and marketing, the team combines its expertise to fulfill all disciplines of the Formula Student racing series. In the competition, the 100 or so teams not only compete against each other on the race track, but also have to prove their skills in static disciplines such as business planning and cost calculation.
Unique prototypes thanks to SLS 3D printing
Almost all of the parts required for the interior of the all-electric racing car are one-offs that have to be produced over a short period of time. "3D printing offers us the best prototyping platform for manufacturing the housings and brackets we use in the car," explains Niklas Rösler. The engineering student was responsible for the vehicle's high-voltage system this year. Due to their complex geometry, many of the required components are usually impossible or very cost-intensive to produce using conventional manufacturing technologies. "SLS 3D printing is the most suitable prototyping technology for us. We can use it in almost every situation relating to the car," says Rösler.
Stable and safe with PA12
SLS 3D printing meets the requirements for almost all automotive applications. Rösler's task was to ensure that the battery cells are well stored and that the system is cooled. To this end, he developed a housing that was printed on the Sintratec S3 using PA12. This component stabilizes the individual battery cells in the rear of the vehicle and ensures a firm hold during rapid load changes and three-dimensional application of force. For use in electric cars, dielectric strength plays a very important and safety-relevant role. To cool the entire system, spacers, also made of PA12, are used to regulate the air flow. "The PA12 material from Sintratec covers most areas of application in racing cars. It offers the best mechanical properties for our purposes, as well as high dielectric strength," explains Rösler.
Constant potential for improvement
The race weekend of the Formula Student main event was visibly exhausting for Niklas Rösler and his team, but nevertheless successful. After initial technical problems, the team achieved a good run in the autocross and also scored plenty of points in the static disciplines. In the overall standings, the team ultimately secured 20th place out of 71 participating teams in the electric class. "We are very proud of the performance, the design of the car and, above all, what we have achieved as a team over the past year," summarizes Rösler. He and his team will certainly be relying on 3D printing again next year.
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