Industry: Motorsport · Automotive Engineering · Student Racing Teams
Technology: Fused Deposition Modeling (FDM)
Application: Steering system prototyping
Equipment Used: 3DGence INDUSTRY F340

Overview: From Concept to Prototype in Under 48 Hours

When the AGH Racing student team prepared for the Formula Student competition in Michigan, they faced tight deadlines and strict cost constraints. Designing a steering knuckle—a complex, safety-critical suspension component—using traditional CNC machining would have been expensive, slow, and geometrically limiting.

Instead, they turned to FDM 3D printing with 3DGence INDUSTRY F340 to quickly validate their design and make real-time improvements before final production.

Challenge ①: Complex Geometry + Tight Budget

Part Type: Steering Knuckle
Issue: Geometry too complex for conventional CNC machining
SLS Cost Estimate: Up to €20,000
Solution: FDM prototype verified assumptions without major financial investment

Challenge ②: Limited Time Before Competition

Deadline: FSAE Michigan approaching fast
Prototype Time with FDM: < 2 days
Post-Processing: Efficient removal of supports using soluble ESM-10
Outcome: Prototype ready in time for judge review and testing

Benefits of the 3DGence INDUSTRY F340

Affordable R&D: Enabled functional testing at a fraction of traditional cost
Time-Saving: Model delivered in < 48 hours, ideal for fast iteration cycles
Creative Flexibility: Allowed engineers to explore shapes unachievable by machining
Educational Value: Empowered engineering students to lead design and prototyping

Conclusion: Enabling Student Innovation Through Additive Manufacturing

By embracing FDM 3D printing, the AGH Racing team avoided costly prototyping delays and pushed the boundaries of their design. The project exemplifies how additive manufacturing can empower student engineering teams to innovate rapidly, efficiently, and affordably—transforming ambitious concepts into competition-ready reality.