Tecnun Motorsport team reduces carbon fiber intake manifold weight by 60%.
January 26, 2022
Stratasys FDM sacrificial tooling contributes to the production process.
Increasing performance.
The University of Navarra sets the benchmark
for high standards in education, boasting Spain’s
highest post-graduate employment rate. Part of
this success is the university’s commitment to
immerse students in as many real-life projects as
possible. One example is the university’s Tecnun
School of Engineering, whose students participate
in the annual Formula Student engineering
competition. Harnessing the engineering skills acquired from
their curriculum, the students compete against
teams from other universities to design and build
a formula race car.
Tecnun’s main objective for
a recent competition was to use 3D printing
to increase car performance. The team quickly
identified the design of the intake manifold as a
crucial element to success and an area in which
the technology could be deployed. However, according to Javier Aperribay, Technical Director of Tecnun
Motorsport, manufacturing an intake manifold is no easy task.
“The design of an intake manifold is extremely complex as it comprises several important components
critical to the air distribution along the four intake manifolds,” he explains.
Introducing Stratasys FDM sacrificial tooling within the production process of the intake manifold allowed us to make it from carbon fiber instead of heavier, less efficient materials.
Javier Aperribay, technical director, Tecnun Motorsport
Overcoming limitations of traditional production methods.
The team chose to manufacture the intake manifold in carbon fiber composites to reduce weight and
lower fuel consumption. Traditionally, manufacturing such a part would require a mold to lay up the
composite materials and create the final part. CNC machining would be used to produce the mold in
aluminum, but this is typically an inflexible and costly process. Any subsequent revisions would delay the
project and add extra costs.
“With aluminum mold production traditionally taking two months, the team recognized the amount of
creativity they could apply to their intake manifold design would be limited, as any iterations to the mold
would be impossible, given the short deadline.”
A 3D CAD render of the complex air
intake design, comprising several
individual components.A 3D CAD render of the complex air intake design, comprising several individual components.
Turning complex designs into reality in a few hours.
To support the university, local Stratasys reseller Pixel Sistemas sponsored the team and produced
FDM sacrificial molds for the students. Using a Stratasys Fortus 450mcTM 3D Printer, a mold tool for
the intake manifold was 3D printed in ST-130TM sacrificial tooling material and wrapped with carbon
fiber composite material. Once cured, the internal sacrificial core was washed away, leaving the final
composite part – a perfect process for the production of complex shapes.
“Introducing Stratasys FDM sacrificial tooling within the production process of the intake manifold
allowed us to make it from carbon fiber instead of heavier, less efficient materials,” says Aperribay. “The
superior soluble characteristic of the ST-130 material enabled a more complex shape of the intake
manifold compared to aluminum molds. The first mold for the intake manifold was 3D printed in just five
hours, as opposed to the three weeks lead time associated with conventional aluminum molds.”
The team also noted that during the curing process the material performed in high temperatures up to
121 °C and, at certain temperatures, pressures up to 620 kPa.
Faster production, more optimization time.
Using the time saved during production, the
team refined the design, achieving a final carbon
fiber intake 60% lighter than one made with
conventional production methods. Putting this
accomplishment to the test, the Tecnun team
took part in two International Formula Student
races, achieving its best finish to-date. As the
team looks to future races there is little doubt that
FDM sacrificial tooling will play a crucial role in
overcoming the next engineering challenges. The final carbon fiber intake manifold employs a
smooth surface finish for increased airflow and
improved track performance.