In the high-stakes world of racing, every millisecond counts. The University of Toronto Formula Racing Team knows this all too well, and for their 2024 season, they turned to FacFox’s cutting-edge metal 3D printing technology to gain a competitive edge. The result? A set of four aluminum (AlSi10Mg) suspension bellcranks that are not only lighter but just as rigid as their traditionally manufactured counterparts.
Revolutionizing Suspension with 3D Printing
To reduce weight in the car’s suspension system, the team collaborated with FacFox to produce these critical components. The bellcranks, which transfer wheel movement to the springs and dampers, were optimized for additive manufacturing. FacFox provided material samples, allowing the team to test and validate the mechanical properties before final production. This partnership marked the team’s first foray into the exciting world of metal 3D printing, paving the way for future innovations.
Harnessing the Power of Generative Design
The team leveraged the latest advancements in artificial intelligence to create the bellcranks’ geometry through generative design. Starting with a basic shape and a set of applied forces and constraints, a specialized algorithm iteratively optimized the structure to handle stresses efficiently. The result was an organic design with curves and contours that traditional manufacturing methods could never achieve, but FacFox’s 3D printing capabilities brought to life.
From Concept to Reality: The Process
- 3D Modeling: Using generative modeling and finite-element analysis (FEA), the team refined the bellcranks’ design to maximize weight reduction while maintaining strength.
- DMLS 3D Printing: FacFox used direct metal laser sintering (DMLS) to selectively sinter powdered aluminum alloy, layer by layer, into the precise shape of the bellcranks.
- Quality Assurance: Rigorous quality control ensured the finished bellcranks met the team’s exacting standards.
- Finishing Touches: The team post-machined the bellcranks to refine critical dimensions, such as bearing bores and bolt holes.
- Final Assembly: Needle bearings were pressed into the parts, and the completed bellcranks were installed on the car, ready for action.
A Season to Remember
The 2024 season was a triumph for the University of Toronto Formula Racing Team. Despite challenges, they constructed a formidable challenger, UT24, and defended their title with a second consecutive victory at the New Hampshire Formula Hybrid + Electric Competition. They also secured a solid 10th place at the FSAE Michigan Electric competition, reaffirming their status as the top-ranked team in Ontario and the second-best in Canada.
Breaking New Ground with Driverless Technology
This season also saw the debut of the team’s independently developed driverless system, a first for a Canadian university and the second rules-compliant system in North America. With driverless technology set to revolutionize FSAE competitions and the automotive industry, this achievement is a significant milestone.
Gratitude and Celebration
The University of Toronto Formula Racing Team extends heartfelt thanks to FacFox for their invaluable support. The metal 3D printing provided by FacFox enabled the team to create lighter, stronger parts, crucial for their suspension system and future designs. FacFox is more than a sponsor; they are a cherished team member and supporter.
UT24 Accomplishments:
- 1st Place Overall at Formula Hybrid + Electric (32 teams) – Design Finalist
- 9th Place Overall at Formula SAE Michigan (77 teams) – Design Finalist
- First Canadian Driverless FSAE Vehicle
Team Milestones:
- Most Followed Electric FSAE Team in North America on Instagram
- Largest Team at Formula Hybrid + Electric and Formula SAE Michigan
- Over 300 in Attendance at UT24 Unveiling
- Featured on 5 News Outlets Including CBC/Radio-Canada
- Attendance at Toronto Honda Indy for 2 Consecutive Years
Achievements Made Possible with FacFox’s Support:
- 10% Mass Reduction of Bellcranks
- 22% Increase in Stiffness of Bellcranks
- 57% Reduction of Compliance in Throttle Position Sensor
- Development of 4 Motor Powertrain using Motor Cooling Sleeve
- Addition of Driverless Brake System using Brake Pedal
Discover FacFox’s Cutting-Edge 3D Printing Services
At FacFox, we specialize in bringing innovative designs to life with our state-of-the-art 3D printing technologies. Whether you’re in the automotive industry, aerospace, healthcare, or any other field, our expertise in metal and plastic 3D printing can help you achieve unparalleled precision and performance. From prototyping to full-scale production, FacFox offers a comprehensive range of services tailored to meet your specific needs. Join the ranks of industry leaders who trust FacFox to push the boundaries of what’s possible. Contact us today to learn how we can help you revolutionize your projects!
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