{"id":31685,"date":"2017-06-09T10:10:19","date_gmt":"2017-06-09T14:10:19","guid":{"rendered":"https:\/\/www.shapeways.com\/blog\/?p=31685"},"modified":"2017-06-14T17:47:35","modified_gmt":"2017-06-14T21:47:35","slug":"warrior-racing-uses-3d-printing-formula-sae","status":"publish","type":"post","link":"https:\/\/www.shapeways.com\/blog\/warrior-racing-uses-3d-printing-formula-sae","title":{"rendered":"How Warrior Racing Uses 3D Printing for Formula SAE"},"content":{"rendered":"

Recently we told you about how Brandon Horsch (a.k.a. AgentArrow<\/a>) makes customized models for the T\u2019au Empire in Warhammer 40,000<\/a>. Brandon is also an engineering student at Wayne State University<\/a> in Detroit, and an active member of the school\u2019s Warrior Racing<\/a> team. Here Brandon explains Formula SAE<\/a> racing and the different ways his team uses 3D printing to compete, from bespoke parts to visual aids.<\/em><\/p>\n

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What is Warrior Racing? <\/em><\/strong>
\nWarrior Racing is the Formula SAE team for Wayne State University. Formula SAE is a STEM-based series which tasks teams of university students to design, build, test, and compete with a small-scale formula-style race car. We compete against other universities from around the world.<\/p>\n

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Steering wheel has a carbon fiber base with integrated quick-release and inset buttons for our shifting paddles into the base. Grips are printed in Elasto Plastic so that they have some flexibility and squish slightly when gripped,\u00a0but still provide firm support.<\/p><\/div>\n

How did you get involved in Warrior Racing?
\n<\/em><\/strong>I had just finished my final year in the FIRST Robotics Competition<\/a> when I discovered the team during freshman orientation. I grew up\u00a0loving cars and living near\u00a0a racetrack, so Formula SAE seemed like a logical next step.<\/p>\n

How do Formula SAE competitions work?<\/em><\/strong>
\nEach competition has a series of static and dynamic events.\u00a0Static events\u00a0are presentations about vehicle design, the team’s business structure, and the cost-effectiveness of the build.\u00a0 Dynamic events include a short drag race, a figure 8 skid pad, a timed autocross, and a combination endurance race and fuel economy evaluation.\u00a0 Final team rankings are determined based on cumulative scores across all of the events.<\/p>\n

How big are Formula SAE cars? <\/em><\/strong>
\nSmaller than Formula Ford<\/a> or Formula 1<\/a>, but still large enough that up to a 95th-percentile American male can fit in one and drive it. They have an approximately 60-inch\u00a0wheelbase and are typically 80 to 100 inches in total length.<\/p>\n

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Throttle pulleys printed in Stainless Steel to test multiple cam profiles.<\/p><\/div>\n

What is your role on the team?\u00a0<\/em><\/strong>
\nI wear a variety of hats. I’m the head of our frame, body, and ergonomics subsystems as well as our CAD lead, PDM server manager, and 3D designer. My responsibilities include designing our tube frame and testing its chassis stiffness, designing and manufacturing our body, seat, headrest, steering wheel, and safety harness mounts.<\/p>\n

I’m also in charge of modeling, exporting, and doing any finishing work or painting of 3D printed components and creating any computer generated animations we use to promote the team<\/a>.<\/p>\n