As the 2024 season of global Formula Student Automotive Engineering (FSAE) competitions begins, university racing teams worldwide are preparing for one of the year’s most anticipated events—the Formula SAE Japan 2024 competition. This year’s competition features 80 official teams, including the Tongji University Electric Racing Team, one of only two Chinese teams granted official entry. On September 9, the TJURacing Team advanced to the Design Report Final (DR Final), marking a significant step forward in their journey this season.

TJURacing Team presenting their business report

In this highly competitive environment, the Tongji TJURacing Team has emerged as one of China’s leading FSAE teams, known for its commitment to innovation and excellence. The team’s challenge has always been to design and manufacture a race car that balances the demands of speed, strength, and adherence to strict competition regulations. This challenge led them to explore new manufacturing methods, especially when faced with producing complex, high-performance components that traditional techniques struggled to achieve.

TJURacing Team vehicle commissioning inspection

This season marks the second time HBD has supported the TJURacing team. Building on the successful results from our previous collaboration, TJURacing team chose to integrate HBD’s metal 3D printing technology into several critical areas of their car, particularly within the chassis and powertrain. Traditional machining methods often face limitations in producing parts with the required precision and complexity. For example, the exhaust manifold, a key component in the vehicle’s powertrain, features an irregular surface and complex internal structures that are nearly impossible to manufacture using conventional methods. By turning to HBD’s metal 3D printing, the team was able to produce a part that not only fit perfectly with the engine’s exhaust system but also met the stringent requirements for gas-tightness and durability under high-pressure conditions.

HBD 3D printed exhaust manifold

In addition to the exhaust manifold, the team also applied HBD’s technology to other critical components, such as the aluminum alloy steering knuckles and the brake and acceleration rails. These components required precise sliding mechanisms and pin positioning, which were challenging to achieve with traditional manufacturing techniques. HBD’s metal 3D printing allowed the team to meet these design needs effectively, resulting in components that functioned seamlessly within the car’s overall design.

HBD 3D printed aluminum alloy fuel rail

HBD 3D printed aluminum steering knuckle