This year’s Formula Student China competition focused on technical innovation as well as driving skills. Several teams, including those from Tongji University (TJU), the Beijing Institute of Technology (BIT) and the Harbin Institute of Technology (HIT), each achieved second place at national level. One common factor: the collaboration with 3D printing specialist BLT (Bright Laser Technologies), which has been supporting student racing teams with additive manufacturing solutions since 2016.
The development focused on structurally optimized vehicle components in which weight, load capacity and thermal efficiency had to be precisely balanced. For example, TJU reworked the steering housing, whose critical joints had a tendency to break in the past. A circumferential connection concept and the use of a high-strength aluminum alloy powder (BLT-AlMgScZr) significantly increased the strength. Production was carried out on the BLT-S600 system, which is designed for larger components with high mechanical requirements.
The BIT Racing Group relied on generative design and topology optimization to redesign steering columns and support structures. The BLT-S400 systems and AlSi10Mg powder were used here. The aim was to significantly reduce the mass while maintaining the same rigidity – a key aspect in motorsport to improve acceleration and handling.
Thermal challenges were also addressed. A customized water cooling system for electric motors was developed for the HIT Racing Team. The integrated Z-channel structure and a modular design increased heat dissipation while simplifying assembly.
The combination of additive manufacturing, materials engineering expertise and student involvement shows how 3D printing is increasingly becoming established as a tool in motorsport construction – not only for the production, but also for the targeted optimization of functional high-performance components.
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