Laser sintering machine and powder producer EOS has played a major role in helping the University of Warwick to move up the field in Formula Students, thanks to extensive use of additive manufacture (AM).
Several years ago, an EOSINT P 380 was purchased to produce optimised plastic components for the race cars in short time frames. Last year, in its role as technical partner, EOS contributed further by manufacturing and supplying laser sintered metal components.
Principal teaching fellow Dr Steve Maggs said: "With the help of laser sintered components made from titanium alloy, Inconel and alumide, last year's team managed to reduce the weight of the race car (fully fuelled) to 192kg, 22kg lighter than the previous year's car.
"The major advantage with AM is that the weight of each component can be optimised and parts can be produced quickly, late in the build process. We hope to make more extensive use of AM in the coming years. With the help of new designs and materials, it should allow us to achieve our target race car weight of 150 kg."
In last year's car, there were three main areas where AM lowered the weight of components. First, titanium alloy and carbon fibre replaced hardened steel in the production of the half shafts driving the two front wheels. Second, Inconel was substituted for steel tubing when producing the exhaust header.
Third, laser sintered alumide, an aluminium filled polyamide 12 powder, was used instead of a casting or fabrication for the induction system. Looking in more detail at the half shafts, their production used to be a headache for the university team, as finalisation of their design always came late in the build.
