PRz Racing Team Intake Manifold
The Formula Student initiative launched cooperation between the PRz Racing Team and OMNI3D, ultimately sparking a project to create a race car using 3D printed elements. Young enthusiasts were tasked with designing and then building the intake manifold of the car, so therefore OMNI3D's goal was to print an element that could be adapted to meet even the most difficult requirements of a racing car.
The biggest challenge was adjusting the collector parameters to the most efficient engine operation. The inlet manifold is an element exposed to vibrations, high temperatures of approx. 100°C and chemicals. Complicated geometry, tightness of the system and its strength and stiffness were all taken into consideration.

A very important factor in guaranteeing success was the attempt to reduce the component's weight when compared to that of traditionally manufactured parts. The selected material had to be characterized by high temperature resistance, but also stiffness. The best solution to this challenge was the use of 3D printing, which offered low costs and the possibility of several iterations of this project in a short time. The model was printed on a Factory 2.0 NET printer using CF (Carbon Fiber) PA-12 filament.​
The first tests confirmed the design correctness and intended efficiency. The carbon fiber reinforced polyamide used provided the necessary strength of the printed element. The 3D printed intake manifold is 1.5 kg lighter than a traditional aluminum component. The data based on the mass point simulation shows that thanks to the 3D printing technology, the weight reduction directly contributed to the better performance of the racing car. ​
INDUSTRY:
Automotive
CLIENT:
PRz Racing Team
CATEGORY:
Prototyping, low-volume production, final product
MATERIAL:
CF-PA-12
PRINT TIME:
65 h
WEIGHT:
570 g (0,2 layer)
SIZE:
​291 x 290 x 226 mm + 291 x 290