The 2024 Formula Student China (FSC) concluded with thrilling performances, marking a milestone for motor racing events. Since 2016, BLT has been a committed sponsor of FSC/FSAE teams, continuously exploring metal 3D printing’s potential in lightweight automotive design and innovation.
In this competition, BLT-sponsored teams—TJU (Tongji University) Racing Team, BIT (Beijing Institute of Technology) Racing Team, and HIT (Harbin Institute of Technology) Racing Team—all secured second prize at the national level. This achievement highlights not only the teams’ technical expertise but also the pivotal role of BLT’s comprehensive support in the design and manufacturing of racing components, which enabled breakthroughs in weight reduction, strength enhancement, and thermal management efficiency.
Enhancing Structure and Performance for Racing Innovation
In high-performance race cars, structural integrity and weight reduction are critical. BLT leveraged metal 3D printing to provide tailored solutions that enhanced durability, reduced weight, and improved mechanical properties for key vehicle components. For TJU Racing Team, BLT helped address structural weak points in the steering housing, where the connections were prone to fractures. By adopting a wrap-around connection method, the revised design significantly improved strength and durability while enhancing mechanical performance.
Additionally, the Dre24 rear pillar was redesigned with a barrel-surrounding structure and printed with BLT-AlMgScZr, BLT’s high-strength aluminum alloy, balancing lightweight design and structural integrity. For brake calipers, BLT applied topology optimization to minimize material usage while maintaining rigidity, further refining the connection structure to achieve both weight reduction and enhanced performance. These components were manufactured using BLT-S600 machine, ensuring precision and superior mechanical properties.
In collaboration with BIT Racing Team, BLT refined the design of critical components like pillars and steering mounts through topology optimization and generative design. This approach enabled significant weight reduction in the parts without compromising strength, which is crucial for meeting the strict performance requirements of racing conditions. These parts were printed by BLT-S400 machine using BLT-AlSi10Mg, ensuring high precision and mechanical reliability for racing cars.
Optimizing Thermal Management for Better Performance
Thermal management plays a crucial role in race cars. BLT supported HIT Racing Team in optimizing their motor cooling system, manufacturing a custom-designed water jacket using BLT-AlSi10Mg by BLT-S400 machine. The design incorporated a Z-shaped water channel, maximizing heat dissipation area. A modular design simplified assembly, while thermal paste-filled gaps further enhanced heat transfer, ultimately extending motor lifespan and efficiency.
BLT’s commitment to motorsports engineering extends beyond sponsorships, unlocking innovation in automotive component manufacturing. In the inaugural BLT Racing Component Optimization Design Competition, TJU Racing Team took first place and BIT Racing Team secured second. The judging panel, composed of industry leaders and experts from leading automotive brands, provided professional insights and guidance, helping student teams optimize their design strategies and manufacturing processes.
With the competition concluding, BLT reaffirms its commitment to pioneering metal 3D printing applications in automotive engineering. By advancing innovation and collaboration, the company invites global partners to join forces in redefining the future of motorsports technology and driving progress together.
