Rapid prototypes give students a racing edge

Edited by the Engineeringtalk editorial team Sep 14, 2004

Operational prototypes manufactures in nylon using selective laser sintering have helped the Oxford Brookes Formula Student Racing team to lead the UK in this year's competitions.

The Oxford Brookes Formula Student Racing team is once again top in the UK in this year's competitions, competing with two cars; the ISIS 03B car in the Class 1 200 Series and the brand new ISIS 04 car in the Class 1 Series.

Attracting press coverage from Sky Sports, Motorsport News and Autosport (Japan), the ISIS 04 car finished 7th overall and was the top UK entrant, beating stiff competition from Lancaster University and other well established UK Formula Student teams.

The ISIS 03B car finished 4th overall in the Class 1 200 series.

3T RPD supplied operational prototypes in nylon to the Oxford Brookes teams, using its selective laser sintering (SLS) technology.

The combined plenum chambers and inlet manifold parts survived the extensive mapping and dynamometer testing intact, as well as all the competition events, demonstrating the arduous service conditions that such parts can be operated in.

The demands of the programme dictate that the students must fully develop an engine on the dynamometer, install it in the car they have designed and built, then undertake a rigorous test programme, before competing in 3-day events in both the USA and the UK.

3T's rapid prototyped components were fitted to a test engine on the dynamometer and underwent a two week extensive engine development and test programme.

During this time the students ran the engine while carrying out the complete mapping process to develop a sound engine calibration map for all speeds and throttle openings.

The engine was then fitted to the car, before the car test programme started.

Once again, several days of testing were completed before the car was shipped to its first competition in the USA where it completed all the events.

Returning to the UK, further track testing sessions were completed before the UK competition took place.

Both cars competed and finished in every event; a remarkable achievement for any Formula Student Racing team, let alone one entering two cars.

In addition, the ISIS group came 2nd in the Honda sponsored "most desirable product prize", the prize including a factory tour around the BAR F1 factory.

The team also picked up 2nd place in the SolidWorks sponsored prize for use of SolidWorks CAD software, including Cosmos analysis software, SW Animation and SW Photoworks.

Howard Ash, Team Projects Supervisor for the Oxford Brookes Racing Team said: "With 67 competitors from all round the world, including the US, Canada, Australia, Japan, Korea and all over Europe, we are extremely proud of our achievements".

"The university has been rated the best British team in the last three competitions they have entered, and our students have come away with a fabulous learning experience".

"We now hope to raise enough sponsorship to compete in the Australian round of the Formula Student competition in December 2004, and are commencing design work on the ISIS 05 car for next season, as the rules demand a new car each time".

Tim Plunkett, CEO of 3T, says: "We are extremely pleased with the results of our SLS components, and the fact that they were used in real conditions further proves the functionality of our prototypes in true working environments".

"Our continuing support of engineering students further compounds our belief that they are the future talent that industry needs, and we are dedicated to developing relationships with them early on and supporting them in their future successes".

3T's involvement with the F1 motorsport industry has already proved the strength, durability and functionality of its SLS parts, allowing them to be used in anger in true working environments, therefore negating the need to go down the more traditional manufacturing routes.