Design &

Engineering
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World Championship 2023

 Table of contents
Constraints/Hierarchy
Research
Testing
Constraints/ Hierarchy
3D Modelling
Design Concepts
CAM/CNC/Manufacturing
Manufacturing/Assembly
Hierarchy
The basic constraints have the highest
influence upon the final results of the product.
Therefore, they dictate the main objective of
the engineering process and all following steps
are supporting elements.
Researching or testing are scientifically,
correctly executed processes, which are used to
evaluate certain elements or design concepts
of the product. Their results decide upon future
corrections of the design or idea.
Based on the results from the upper levels of
the hierarchy, design concepts are created to
specify certain aspects of the car. They range
from certain measurements of the car to
material choice. These are again divided in the
basic and advanced part.
Force analysis Basic constraints
8 grams of Carbondioxid leaving the gas cartridge puts the car in Taking the results from the force analysis, there are some basic
motion. There are multiple forces working upon the vehicle. constraints about the engineering process, which can be fixed from
the beginning.
1
Minimal Mass (>50g)
The force sourcing from the ignition of the gas
cartridge should be fully used on the acceleration
2 of the car.
As visible in this formula, the bigger the mass [m],
the smaller is the force [F] used for the
3 acceleration [a].
On the other hand, the possible maximum speed
reached by the vehicle also reduces due to higher
mass. The kinetic energy [Ekin] used to move the
4 ▶ Forces working upon the car; Credit: Excelleration car gets divided into the velocity [v] and the mass
[m] of the car. Similar to the upper equation, the
The cyan arrow shows the force generated by the gas cartridge. This bigger the mass, the smaller the possible velocity.
5-8 force can not be manipulated. The black arrow represents the
gravitational force working upon the vehicle. And the Grey arrow Technical Regulation
demonstrates the Force with the vector in the opposite direction of The highest priority does not lay in the speed of the car, but in the
the cyan vector, it also contains the force used to initialize the car to compliant of the technical regulation. This factor affects the final
move. results the most.
9
After throughout analysis of the possible combination, the following Stability
elements can be found influencing the vector. The car shall not receive any damage during or after the race. The
possible consequences shall not occur.
10 - Air resistance (Aerodynamics)
- Friction Implementation
- Wheel to Track A great idea without implementation is useless. One must always
- Tether line to guide consider the aspects of cost, time and possible method for
- Bearing realization during the engineering process.
- Inertia of the wheels
- Car mass
One main objective of the engineering task is to reduce the
mentioned force generated by the listed elements. Engineering phase
The entire process of engineering was divided into two phases. The
Constraints
first phase was about the planning, designing and the virtual testing
process of the vehicle. The second phase was rather about real-life
testing of the prototypes and the final manufacturing of the car.
Research
Tests
Design
Concepts
▶ Hierarchy;
Credit: Excelleration
1
CONSTRAINTS / HIERARCHY

Research
Certain expertise is necessary to build a fast car. Therefore,
we collected the following categories as the focus during
research. From this given knowledge, we developed further
specific design concepts.
Basic aerodynamic
The aerodynamics defines the behavior of an object in air. The main
focus here lies on the air resistance force. This force needs to be
reduced and the following needs to be considered:
Cw= Drag Coefficient
A= Area of Resistance
p=Density of fluid (air=1.2 kg/m³)
v= Flow velocity
In this case, only two values can be changed, the Drag Coefficient
and the area of resistance. In both case, those values need to be
reduced.
▶ Front area of former designs; Credit: Excelleration
Reducing the area of resistance can be achieved by taking minimal
measurement on the attacking side of the vehicle. (e.g., diameter of
the cartridge chamber or wheel.)
The drag coefficient is a proportionality constant, which describes
the aerodynamic feature of an object. This coefficient can be
determined by experiments. The smaller it is, the more aerodynamic
the object.
Research
Cw 0,4 1,4 0,5 0,05
A spoiler profile has the smallest drag coefficient in the usable forms,
therefore, the spoiler profile form shall be applied in as many
occasions as possible, such as holding elements. Furthermore, a
smaller angle of attack for the areas also benefits the decrease of
drag coefficient.
Advanced aerodynamic
Reynolds number represents another important proportionality
constant for the fluid dynamic. This number describes the
proportion between the inertia force and the viscosity of the object.
Using the Reynolds number, one is able to describe the
characteristics of the vehicle even more precisely.
The characteristic length [d] of a F1 in schools
Directional tolerance
car lays around 2·10^-3 m to 3·10^-3 m, while
the air pressure [p] and velocity of flow [v] are
Firstly, the car never points with an angle of 0,0° to the finish line.
constant. Through calculations, the Reynolds
Secondly, through observations, it is also noticeable, that the car
number a F1 in school's car finds itself in the
shows tendency of lightly turning due to minimal imbalances in the
area between 2,9·10^3 to 3,5·10^3. This
systems. The car then utilizes a part of the energy to rotate the
information can be used in two specific areas.
vehicle again to point it forward again. This energy needs to be
minimal.
1. The flow types in the fluid dynamic can be divided into laminar
and turbulent flows. In our use case, laminar flow would be
The longer the rotating arm [h], the smaller the force [F] necessary
preferable in the environment. The characteristic of constant and
for the same amount of torque [M]. The car has two rotating arms,
periodic flow is optimal for a frictionless drive. A turbulent flow
the wheels, and the tether line guides. Both of these elements
behaves chaotic and causes turbulences to appear, which is
should have maximum distances between each other to achieve a
suboptimal for a smooth drive and energy efficiency. Reynolds
maximum arm length.
number usually lower than 2300 in a system cause turbulent flow to
appear less frequent, therefore, the characteristic length of the
vehicle could be used to lower the turbulences.
The flow of air can also be used to correct the direction of the vehicle.
The graphic demonstrates the influences of vertical areas on the
vehicle, influencing its rotation. Vertical areas in front of the center of
▶ Laminar turbulent
mass (COM) would misdirect the vehicle even further, while a force
flow; Credit: RWTH
Aachen in the rear of the COM would correct the car's wrong turn.
2. The Characteristics of spoilers is the other feature influenced by
the Reynolds number. The website “airfoiltools.com” provides ▶ Forces, torques, and
simulation results including drag or lift coefficient of over 1600 their influences; Credit:
airfoils at different Reynolds Number. Using the calculated Reynolds Excelleration
number in our case, we are able to select a spoiler with low drag
coefficient and an optimal lift coefficient. For more information
about the selection, see: Spoiler p.9
In an optimal case, where Mrear > Mfront, the drive stays stable. To
▶ Airfoil; Credit: Airfoiltools.com
achieve this, it is necessary to increase vertical areas behind the COM
and decrease vertical areas in front of the COM. Furthermore, a
Slipstream describes a zone, in which the air velocity is relatively longer distance of these vertical areas behind the COM would also
low. Those areas typically find itself in the opposite direction of the benefit to increase Mrear.
wind. For our case, it was critical, that the slipstream covers the
moving parts of the vehicle, which are the wheels. A lower air speed
for the wheels guarantees a relatively frictionless rotation. This can
be achieved by using certain parts to cover the wheels, such as the Center of mass
side pods or spoiler.
Through observations, one realizes that a rotational force upwards at
▶ Redirection of the air stream
the rear end of the vehicle exists during the start of the race. To
creates a slipstream behind the utilize the maximum amount of force [F] given by the cartridge, the
side pods; Credit: Excelleration
location of the COM must be as close as possible to the height of the
CFD
cartridge to prevent this rotation.
F
s
Optimal rotation ▶ COM of the vehicle; COM
Credit: Excelleration
A certain amount of energy is used to set the wheels in motion
during the start of the race. This energy, described as rotational
There are multiple measures to achieve this, for example specific
energy [Erot], shall be minimal.
material choices for certain parts or decrease of volume on the
bottom side of the vehicle. Furthermore, a wider wheelbase can also
be helpful to increase stability.
Given that the angular velocity [w] stays constant, one must reduce
the torque [J]. To achieve this, the diameter and mass of the wheel
and all rotating objects shall be as small as possible.
2
RESEARCH
 The depiction in portfolio is significant to mention in terms to
Friction
Testing understand future graphics. The following schemes were repeatedly
used:
Basic theories are good foundations for knowledge, but Due to the issue, that given indicators such as coefficient of friction
Static Pressure in Pa Air speed in m/s
more information is needed to complete a design. For this, never deliver exact realistic results due to issues such as surface
Application: Areas of vehicle Application: Level, Trails
we use multiple testing methods to confirm or deny the quality or air humidity, we developed the friction testing method to
usability of designs. determine the most effective materials to use as tether line guides
on our vehicle.

This method determines the usability of different materials as tether

line guides. A tether line with a diameter of 0.4 mm is set up in a 30°
downwards angle on a distance of 2m, The different parts are
CFD loaded with a mass of 50g and inserted onto the module. The
smaller the measured time, the smaller the friction. The results of
The use of Computational Fluid Dynamics (CFD) software provides this test can be found in Advanced DC: Tether line guides.
information about the aerodynamics of the vehicle in a simulation.
The following programs were compared: ▶ Left: The tether line set up
▶ CFD simulation of Excellence 22-2 including scales: Excelleration CFD
with materials; Credit:
- In comparison rather Excelleration
+ Precise results
- Long durations
imprecise
- Only usable with
Wind tunnel ▶ Right: Some of the tested
materials; Credit:
- High error rate simulated Linux Excelleration
(Ubuntu) This year, we had the opportunity to corporate with the Technical
University of Hamburg-Harburg. There we had the opportunity to
+ Rapid, precise results + Super fast results utilize their wind tunnel for our testing purposes. Using that, we
+ Many analysis tools + Simple application were able to predict air resistance forces in forehand at various
- Some error messages - Imprecise Results velocities. Using the real life testing method, it was possible to Wheel Integration Test (WIT)
illustrate the changes in a more understandable way.
We came to the conclusion to utilize both Autodesk CFD and Flow The virtual tests are not enough to confirm the stability of wheels.
Design. Combining both, quick information can be gathered ▶ Left picture: Measured resistance force; Deformations or damage shall not occur during and after the racing
Credit: Excelleration
through Flow Design, while throughout analysis is possible with event. To confirm this, we applied a mass based testing method to
CFD. test the maximum capacity of a wheel's design and material choice.
▶ Right picture: Wind channel;
Credit: Excelleration
The higher the mass capacity of these wheels are, the more durable
The following procedure was taken for every single test using they are.
Autodesk CFD:
Markings are made on the device in forehand to have comparable
1 Export of data into sat. format from Solid Edge for an easier post-processing. (
Solid Edge simulation results. The first limit of the wheels is set at the points where the
Only one volume, not 300 areas as in iges or stl. deformation exceeds 5 mm. The second point is the moment where
The utilized CAD program Solid Edge included the feature of a virtual the wheel enters a plastic deformation.
2 simulation of parts under force collisions. This simulation was fast
Determine air speed and pressure of the surrounding environment. 22 km/h air
speed at front and pressure at rear and was used to simulate the stability of certain vulnerable parts of The masses are added in 50g steps until the first limit of the wheel is
3 the vehicle during the construction to prove the usability of ideas. reached. For the second limit, the masses are added in 100 g steps.
Selection of material, air for the environment, the material of the parts are
irrelevant for the results, as long it's solid.
After every mass addition, the wheel is being taken out and
inspected after deformations.
1 Firstly, the correct material properties must be selected. A wrong value could
4 Definition of the volume grid, important step, because the fineness of the mesh falsify the entire simulation. As an example, the following values were selected for
is being determined by this step. There must be over 1.5 million mesh points in the material Polyamide 12:
the net system. The finer this net, the more precise the results.
▶ Values; Credit:
Excelleration
2
Testing

Furthermore, after the meshing and fixing points, the simulation can start. But
Test 500–600 scenarios provide precise final solutions at the end. before that, it is necessary to know the force worked upon the vehicle.

For example, the maximum force Another possible vulnerable point of the vehicle can
working upon the car can be be found in the wheel system. But sure enough, the
These tools were utilized to analyze the results afterward: calculated with the velocity, mass, forces working on these parts are smaller.
and time to decelerate of the car.

▶ A alternative system's
m= mass deformation at ▶ A wheel prototype being tested; ▶ Permanent deformation of a
v= velocity 5 N; Credit: Excelleration Credit: Excelleration prototype; Credit: Excelleration
t= decelerate time

Using a light modification, the device can also be used to test the
Local Pressure Level Particle tracks Pressure calculator Report
The most important observation is to detect whether a spot exists with bigger Halo integration. Due to the newly introduced regulations, the halos
Results pressure than the Yield Stress. From that point on, the material has potential must withstand the force generated by a mass of 1 kg. This was
As for Autodesk Flow Design, we utilized a similar principle, the to break. A new concept for higher stability must then be considered.
tested using various materials to check the compliance of these
difference is, that the analysis is 15 times quicker. Therefore, only the materials.
local pressure and particle tracks tools are usable in this application. ▶ In this demonstration, the part shows
minimal deformation at a force of 20N,
which proves the concept to be
theoretically feasible; Credit: Excelleration

3
TESTING

3D Modelling
The term of 3D Modelling contains more than the simple
construction of the final vehicle. The choice of software,
the correct type of data and further modelling techniques
are all parts of this simple topic. One must also always
consider the final form of manufacturing while designing
the individual parts. Different boundaries in reality might
conflict with the endless possibilities in the designing
process.
Modelling techniques Compliance for CNC
There are multiple techniques available to re-/model an object in Through our cooperation with the Helmut-Schmidt University of
Solid Edge. But firstly, one must decide between the synchronous Hamburg, we had the opportunity to get access to a five axis milling
and sequential modelling methods. For an optimal workflow with device. Powerful as it is, we still have certain boundaries during
order, we decided to apply the sequential modelling to keep track of manufacturing. To comply the design with the process, the following
all changes. Furthermore, the designs based on sequential are tools were used:
history based and therefore, changes to previous steps can directly
influence future designs. This was helpful in most cases, because Draft Face Analysis was a simple tool used
further changes in past steps were unnecessary anymore. to analyze all areas given on the vehicle.
Specifically, the adjacent areas between the
The next decision was to decide between surface modelling and colors are the spots, where the focus lies. ▶ Draft Face Analysis of chassis
solid modelling. On the one hand, the biggest benefit of surface Flawless transitions are necessary. ; Credit: Excelleration

modelling is the high precision modelling with endless possibilities

coming along the deformability. But after trying out, the frequent Geometry Inspector is another tool used to
errors made it difficult to be used efficiently. check the model. Errors or sharp edges ▶ Inspector
Solid Edge which can be found before the setting
On the other hand, the alternative of solid modelling seems manufacturing using this. One is able to screen; Credit:
Excelleration
CAD (Computer Aided Design) are programs used to create drafts restricting at first, but using further methods such as lofted determine the minimum edge length, face
or models of objects. Our final choice was Solid Edge 2023, a protrusions or rounding gives this method equal opportunities. radius and furthermore while inspecting.
software developed by Siemens. This program was chosen due to
several reasons, such as the positive experiences using it and also the In the following is the process of creating lofted protrusions, one of Zebra stripes were used to detect smaller,
given features meeting the expectations of our application. Other the most used modelling technique during construction: hardly visible areas, usually generated by
alternatives such as Autodesk Fusion 360 or FreeCAD were denied lofted protrusions. As mentioned before,
due to lack of experience and unfamiliar workflow. 1 those areas are suboptimal, therefore must ▶ Zebra stripes on vehicle;
Fixing of two or more sketches at Credit: Excelleration
the desired locations using ▶ Creation of be eliminated when detected.
parametric design. They must sketches
The following basic features were especially useful during design: ; Credit:
share the same shape (Equal
Excelleration Next to the features in solid edge, more considerations were made to
amount of edges and angles)
make the vehicle easier to be milled with appropriately. For example,
The assembly function 2 certain edges were rounded or reformed to apply to the forms of the
generates a metric Using the lofting tool, one ▶ Connection of
connects these sketches and sketches
milling head, see more on: CNC/CAM.
Multi-Body- File (.asm) out of selects a starting point in these ; Credit:
various metric Single – Body sketches. Excelleration
For example, on the bottom side of the
– Files (.par). This was optimal vehicle, the marked edges were remodeled
3
for multiple uses such as the Now one can modify the final due to inconvenience for the
visualization of the shape, using either the ordinary ▶ Form of curve
manufacturing. Many more roundings were
or selected form of curve. This ; Credit:
assembled parts, mass essential step provides the added to make the vehicle easier to
3D Modelling

calculation or Renderings.
Parametric Design is
another necessary part of
effective construction. The
feature Smart Dimension
gifts the user the ability to
quickly and easily redefine
certain measurements.
Furthermore, boundaries can
be set by using variables to
comply with the regulations.
Additionally, an efficient
sketching tool for drawings
are also essential. Solid Edge
provides a tool to create a
metric drawing file (.dft). The
different methods possible,
for instance detailed drawing
or exploded view, are all
necessary for regulation
compliance.
▶ Assembly File opened in Solid Edge ; Credit:
Excelleration
▶ Chassis File with measurements
; Credit: Excelleration
▶ Excellence 22-2 in dft. format
; Credit: Excelleration
Excelleration
numerous possibilities.
manufacture using the milling machine.
Finally, the biggest advantage during construction using the method was ▶ Bottom side of the vehicle with marks;
Result the benefit for testing. Complicated remodeling for possible designs were Credit: Excelleration
unnecessary. One can easily find alternatives by changing values of the
curve or sketches. Keyshot
Rendering is another essential part of the design process. Solid
Mirrored modeling was another technique used to ensure the
Edge brings the educational version of Keyshot with the download.
symmetry of all parts designed. To avoid any possible mistake
This 3D rendering software by Luxion is a strong alternative in
occurring while designing two sides, everything is only being
comparison to other pieces of software such as Blender or AUtodesk
constructed on the right side. Later, the designs are all mirrored on
Fusion 360. Changes in Solid Edge can be directly imported into
the vertical level. Afterward, imbalances can be found using the
Keyshot without the need to ex-/import. In addition to that, more
center of mass tool.
than thousands of high quality pieces of resources are available on
the Keyshot cloud space, which simplifies the rendering process
while still keeping a high quality.
▶ Rendering of Excellence 23-1
on track, rendered using
Keyshot;
Credit: Excelleration
▶ All designs are being selected ▶ X=0, therefore the model is
to be mirrored; Credit: perfectly symmetrical;
Excelleration Credit: Excelleration

4
3D MODELLING
 Main body The inward curved side pod as a
solution to fix the mentioned
Design Concepts Before thinking of any detailed designs, one must decide which
pressure issue indeed reduces the
direct impact, but on the other hand,
Design Concepts (DC) are detailed construction basic shape the vehicle must take. Here again, we follow the the pressure under the vehicle
regulations. The constructions here are based on the knowledge of the aerodynamics. increases enormously creating two
constraints, researches, and tests. The Design concepts are
As the regulations dictate, the minimal radius high pressure zones.
divided into one basic part and one advanced part. All ▶ Bottom view of the inward side pods;
Resistance Force 0,462588 N (-0.0%)
constructions went in the same order as mentioned in the of the chamber needs to be 12.25 mm. Credit: Excelleration CFD
Furthermore, due to the newly introduced ⇾ Targeted approach
following diagram.
Halo regulation, the depth of the vehicle also
needs to be increased to a minimum of 13,175 Inlet side pod was the solution to
mm, the width of the main body also needs to combine the benefit of both designs.
be increased to > 25 mm to match the safety The high pressure in the front area of
Basic Advanced device. Overall, the smallest measurements ▶ Main body with
measurement;
the side pod is reduced due to a wide
were always taken to reduce the area of Credit: Excelleration flow area. In addition, this flow is
resistance. being redirected to the rear end of
Measurements Wings the side pods. Statically, the
DC

Except the area of resistance, the form of the main body also needs resistance force reduced by another ▶ Bottom view of the inlet side pods;
considerations. The bottom side of the vehicle takes a similar form to 6.7 % in comparison to the inward Resistance Force 0,431737 N (-6.7%)
Credit: Excelleration CFD
the mentioned airfoil form to achieve the mentioned minimal drag curved side pods.
Main Body Wheel system
coefficient, see Research: Basic Aerodynamic.
Moreover, various improvements
▶ Lower main body in simulation; were applied to the final version,
Side Pods Tether Line Guide Credit: Excelleration CFD
including more rounded edges and a
slightly bigger inlet. Lastly, the inlet
side pods were the final side pods on
For a flawless connection to the nose cone, a similar design to the
the Excellence 23-1.
real Formula One vehicles was used as inspiration. The lower nose
Measurements cone leads to an improved connectivity with the front wings. Due
to the concern of stability in front, it was decided to rather utilize the
▶ ISO-View of the inlet side pod concept;

newly invented halo stopping mechanism during the race. This Halo Credit: Excelleration CFD

Certain measurements of the vehicle can already be decided in

new mechanism also allows us to even thinner the front areas to
forehand due to the regulations and the conducted researches: The implementation of halo is a huge
L2 reduce the area of resistance without the concern of the front
potentially breaking. change in design of the vehicle. This
year, due to regulation changes, there
are two available halo design options
Side pods which can be used. Both options
were tested and the option with the
lowest drag resistance was selected. ▶ V1 Halo in simulation;
Side pods design follows two main objectives. To create slip stream
Resistance Force 0,0830093 N
for the rear wheels and redirect the air while not causing turbulence. Credit: Excelleration CFD
The results show, that the second
Therefore, the following designs were tested (The side pods were all
L4 version of the halo delivered a
tested with V1 Halo, all the other tests conducted later were all with
slightly smaller drag than the first
L3 V2 Halo):
L1 version. Therefore, that was applied to
all tests afterward and final vehicle.
Basic DC

▶ Excellence 23-1 with measurements ; Credit: Excelleration The lightly curved pod was the first
idea. It was to adapt the shape of the
Length of the car: Maximum, see Research: Directional Tolerance upper main body. This concept was
L1⇾ >220 mm quickly discarded due to the small Furthermore, the question also lays in ▶ V2 Halo in simulation;
vacuum zone created in the pocket the material of the halo. The stability Resistance Force 0,0803938 N (-3.2%)
and weight both play essential roles Credit: Excelleration CFD
Width of the car: Minimum, see Research: Basic Aerodynamic of the curve. This low pressure zone is
L2⇾ As close as possible to the regulation, ≥65 mm completely unnecessary and disturbs in this case. See all the available
▶ Bottom view of the curved side pods;
the stability of the drive. Resistance Force 0,491795 N
materials in Advanced DC: Materials.
Wheel Diameter: Minimum, see Research: Optimal Rotation Credit: Excelleration CFD

L3⇾ Regulation, ≥28 mm The straight pod was the next After some tests using the modified
option. Here the issue rather laid on wheel integration test, we decided to
Wheel Width: Minimum, see Research: Optimal Rotation, Basic the strong pressure on the front side utilize Polyamide 12 as the final
Aerodynamic due to the higher area coverage. This material for the vehicle. The
L4⇾ Regulation, Front ≥13 mm, Rear ≥17 mm generated an enormous amount of extremely low density (1,01g/cm³), in
resistance force. addition to promising test result,
Ball bearing Diameter: Minimum, see Research: Optimal Rotation, withstanding far more than the ▶ Some different material options for
▶ ISO-View of the straight pod concept; the halo
⇾Technical boundaries, 5 mm desired 1 kg made it optimal for this Credit: Excelleration
Resistance Force 0,462646 N (-6.2%)
Credit: Excelleration CFD occasion.
Side Pods Width: Minimum, see Research: Basic Aerodynamic
⇾Regulation, ≥55 mm
5
BASIC DC

Wings DC
The regulation of this year offers a lot of opportunities for
innovations at the spoiler areas. Triple or single spoilers?
Which support structure? Those are all issues needed to be
solved on these essential parts of the vehicle.
Spoiler type
As mentioned in Research: Advanced Aerodynamic, using
“airfoiltools.com” gave us access to a large database of possible
spoilers. The following information was available:
This diagram for example demonstrates the drag
coefficient of a spoiler in relation to its angle of
attack (AOA). Multiple graphs are visible in this
case, but only the cyan one is relevant in our use
case due to the Reynolds Number. The low
Reynolds Number range available here is 0 –
50.000, which is the closest to the Reynolds
number of our vehicle.
After considerations, those spoilers came
alternatives:
Drela AG04 excels in the matter of low drag
coefficient. Even at an AOA of 0°, the drag
coefficient still reaches an excellent low of
0,01453. But the issue with this specific
spoiler laid in its shape. To make a spoiler
conform to the regulations, the form has to
reach a certain proportion. Otherwise, the
chord or thickness would be exceedingly
large, which would come into difficulties with
other parts or regulations. In this case, the
chord represents the issue.
NACA 0015 as an opposite fixes the
mentioned flaw due to in compliance with
Wings DC
Front wings
Before thinking of any detailed designs, one must decide which
basic shape the vehicle must take. Here again, we follow the
knowledge of the aerodynamics.
Plain wings with small end plate is the simplest
concept in our usage case. The major issue with
this design is the missing slip stream for the
front wheels. As mentioned in Research:
Advanced Aerodynamics, a lower air speed
would be esessential for the moving parts.
Furthermore, the spoiler also creates large
low-pressure zones on the side of the wheels,
which further decreases stability.
▶ Plain wings with small end plate in Autodesk CFD;
The second option was the curved single wing
with larger end plates. After repeated testing,
this prototype still does not deliver the desired
area coverage. Another issue is the support
structure of this design, this comes in conflict
with the tether line guide in the middle part of
the wing. But the larger end plates prove to be
successful in reducing the low-pressure zones on
the side of the wheels, this concept was
therefore set as a targeted approach.
▶ Cd v Alpha diagram of
LOCKHEED L-188 ROOT; ▶ Curved single wing with larger end plates in Autodesk CFD;
Credit: Airfoiltools.com
into question as To fix the issue of the area coverage, the idea of
the triple spoiler concept, realized by this year's
regulation, was tested out Firstly, large
improvements can not be found due to the
misplacement of the wings. But this prototype
gives the necessary information about the
design of a triple spoiler concept, which was
▶ Cd v Alpha diagram
rarely done before. This concept in connection
and the cross-section of with the larger end plates was set to be the
targeted approach.
Drela AG04;
Credit: Airfoiltools.com
▶ Triple spoiler concept, firstly tested in Autodesk CFD;
The connected triple spoiler solution was the
result of further testing. The middle of the spoiler
was split apart to let through the tether lines. To
increase stability of the wings, a vertical
connection part was added, which also has the
Rear wings
The rear wings represent another important structure of the vehicle
in consideration of drag and area of resistance. The main target here
is to reduce both to have a minimum additional drag force.
Therefore, the concept of double rear wings was quickly abandoned
due to its additional unnecessary drag.
The concept behind the support
structure was a minimum additional
height of the vehicle with minimal
additional area. Therefore, the folded
curve shape was applied for regulation
▶ Folded curve shape rear wing
design for reduced height
compliance. The 5 mm airspace around Credit: Excelleration
the spoiler is being guaranteed this way.
Resistance Force 0,47317 N
Credit: Excelleration CFD
Furthermore, to reduce the drag
coefficient of the support structure,
these are then also built in the form of
the spoiler Lockheed C-141. This shape
additionally reduces the occurrence of
turbulent flows. Due to the isolated
location of the rear wings, these can be
▶ Generation 1 Straight Wings;
tested purely without the influence of Resistance Force 0,0275362 N
other parts of the vehicle. Credit: Excelleration CFD
Resistance Force 0,446788 N (-5.6%)
Credit: Excelleration CFD
Firstly, the idea was to use a basic
straight spoiler. But after some
considerations and research, the design
concept of arrow shape appears. The
shape of the feather on an arrow
stabilizes its fly constantly. This ▶ Generation 2 Arrow Wings;
Resistance Force 0,023438 N
inspiration was then included in the (-14.9%)
second generation. Credit: Excelleration CFD
▶ Illustration of an arrow
Credit: Excelleration CFD
Resistance Force 0,416472 N (-6.8%)
Credit: Excelleration CFD
The attachment of the spoilers were also designed as small as
possible to reduce further resistance areas. Due to the regulation of
chamber safety zone, the attachments are visible from the front and
rearview. But through optimizing process and the support of
attachment tool, the attachment feet reached a frontal size of only 1

the regulation. But the large cross-section
causes the issue of larger resistance force.
The lowest drag coefficient of this spoiler is
reached at an AOA of -3,75° or 3,75°, with a
value of 0,02691. This is almost the double of
the previous alternative Drela AG 04.
Therefore, this issue quickly proves large
thickness spoilers as unusable.
Lockheed C-141 was the final option after
careful considerations. It fixed both issues of
all of its previous alternatives. Firstly, the
proportion of its cross-section fulfills the
desired size. Therefore, no extraordinary large
chord or thickness were necessary.
Furthermore, the drag coefficient of C-141 is
either significantly lower than NACA 0015. At
an AOA of 0°, C-141 delivers a drag coefficient
of only 0,02237. This balanced solution was
used on all spoilers on the vehicle, and also
support structures as much as possible.
feature to regulate the flow of air around the
mm x 2 mm.
wheel. The depiction from the test shows a
reduced pressure zone on the lower half of the
▶ Cd v Alpha diagram wheel in comparison with previous wings.
and the cross-section of
NACA 0015;
Other applications
Credit: Airfoiltools.com ▶ Connected triple spoiler concept, firstly tested in Autodesk CFD;
Resistance Force 0,403741 N (-3.05%) Next to the spoilers, there are some more
Credit: Excelleration CFD
possible applications for the spoiler
To prove the lower pressure zone behind the spoiler, a level can be used to measure shape. For example, the attachment for
the air speed behind the wings. The result show, that the spoiler indeed effectively the tether line guide were modified in
reduce it in comparison to the surrounding areas. Furthermore, one final change was
made at the end plate to achieve regulation compliance in the width of the car. The the shape of the raindrop to reduce the
additional end plate wings also support the regulation of the air flow around the drag coefficient while regulating the flow
front wheels. of air on the lower side of the vehicle.
Furthermore, this design was not applied
▶ Cd v Alpha diagram ▶ Left: Relatively low air speed to the wheel support systems, due to the ▶ The support structure of the
and the cross-section of behind the spoiler;
Lockheed-Georgia C-141 Credit: Excelleration CFD design concept of the holding structure wheels and tether line guides
with applied spoiler design
transonic wing; of the wheels which also contains an Credit: Excelleration
Credit: Airfoiltools.com ▶ Right: Extended end plates for
regulation compliance
entire axis going through the support
Credit: Excelleration CFD system.

6
WINGS DC
 PETG, as a modified form of polyethylene terephthalate
(PET) has the advantage of great optical quality due to its Wheel's
various choice of colors. The production would be free
Advanced Design Concept due to the manufacturing using the school's own 3D
▶ PETG Wheel;
Credit:
design

Printer Ultimaker 3. The issue of this material lays in its Excelleration

The advanced Design Concepts containing wheel system uneven and scratchy surface, which is extremely Wheel's
and tether line guides, do not only include the CAD part, unfavorable due to the desired smooth surface area for a material
but more important, the material and real life test. The smaller friction.
results of these mentioned tests will then be presented in
the following. PLA, the most sustainable option of the given materials 0,5 kg 0,4 kg 0,55 kg 0,4 kg
due to its ability to naturally degrade. Similarly to PETG, PP
the manufacturing would also be cost free using the ▶ PLA Wheel; 1,2 kg 1 kg 1,2 kg 1,1 kg
Ultimaker 3. But here the same issue of uneven surface Credit:
occurs again. Furthermore, the high density of 1,43g/cm³ Excelleration
makes this option unusable for a light wheel.
1 kg 0,8 kg 0,9 kg 0,85 kg
Duraform Pro X PA12, is an alternated version of the PA2200
2,4 kg 2 kg 2,5 kg 2,1 kg
Wheel support system usual PA 12. The biggest benefit of this material is its
incredibly small density of 0,95g/cm³. But the stability of ▶ Duraform
this material suffers under the circumstance of the given Pro X PA12

There are multiple alternatives to make the wheels rotate, but there form. The high vulnerability of this material was quickly Wheel; Credit:
2 kg 1,9 kg 2 kg 1,85 kg
are more considerations necessary, including the final
exposed. Additionally, the production cost of 10 Euros per
Excelleration
PC-ABS
wheel makes this choice financially unattractive. / / / /
manufacturing difficulties, stability and rotational weight.

One of the previous solution was the use of a

separately manufactured inlet as axle and use only
one bearing wheel to support the wheel. But soon
enough the disadvantages showed. Only one bearing
made the wheel flicker frequently while in rotation.
Moreover, the metal axle's tolerances were not as low as
expected, while still coming at a high cost to finish. Due
to these reasons, this concept was quickly abandoned.
Credit: Excelleration
No Glue Concept was an innovative concept used
mainly to prevent any glue being used in the system to
easier the final assembly of the vehicle. The two
bearings partially fixes the issue of flickering rotation.
Overall, this concept was considered usable till the
regulation brought out the wheel integration test. The
idea of the test made this concept unusable.
Furthermore, the distance between the bearing wheels Credit: Excelleration
are still too little to achieve optimal rotational stability.
Advanced DC
Due to the mentioned reasons, the materials choices above were 1 kg 0,9 kg 1,1 kg 0,95 kg
quickly abandoned due to the basic impracticalities. Those PA 12
upcoming options were then manufactured in the four wheel
1,8 kg 1,5 kg 2,2 kg 1,6 kg
designs, evaluated and tested using the Wheel Integration Tests, see
▶ Inlet Concept more on Research, Wheel integration test.
(Hamburg, 2021); After the evaluation, the final wheels used on
PP, Polypropylene, is the most flexible tested in the series the vehicle were the vibratory ground PA 12
with great and smooth surface qualities. The deformation wheel with 9-hole weight reduction designs.
▶ PP Wheel;
of the wheel set in quickly after a relatively small amount Credit: The test delivers promising results of stability
of mass. This deformation quickly turned plastic after
Excelleration with a low weight of 1,807g ( second lowest of
small additional masses, which made this option rather
unattractive as wheel materials. all tested wheels). Connected with the axis
rotation concept, the entire rotational mass on
▶ No Glue Concept PA 2200, was one of the most competitive alternatives. the rear end comes to 3,92g, including both
(Germany, 2022); The test delivers promising results for the plastic
wheels and the carbon fiber axis.
deformation limits. The surface can also be flattened ▶ PA 2200
using vibratory grinding. But ultimately, the deciding Wheel; Credit: ▶ Engineering drawing of the

factor against this material was the unfavorable Excelleration 9 hole design wheel; Credit:
tolerances during manufacturing. This point leads to a Excelleration
Axis Rotation Concept fixes the mentioned issue of
instability during rotation through the long distances
higher risk of regulation violation. Axis material
between the two ball bearings. Those are both applied PC-ABS, was the most robust material of all tested
onto the vehicle itself, while an axis goes through it materials. The plastic deformation limit was never The material of the axis also plays an essential role in the support
connecting the wheels. This concept was the final one, reached using the available weights. But the biggest ▶ PC-ABS
which was applied on the vehicle. Although the mass of Wheel; Credit: system. A low tolerance, low weight and high stability are the key
issue with this material is the uneven surface, featuring
the axis is additional to the wheel, still this concept multiple bumps. Furthermore, the high density of 1,1 g/
Excelleration characteristics necessary:
fulfills all requirements mentioned. ▶ Axis Rotation Concept;
Credit: Excelleration cm³ made this option unusable.

PA 12, delivered, mediocre results during the test, but the

The longer the distance between the bearings, the
more precise and fixed is the wheel's rotational
direction. Furthermore, the benefit of a separately
manufactured axis is the option of a lower tolerance of
the material. From experiences, the 3D printed axis
often have small unevenness on the surface, which
▶ Different placement of axis;
could be devastating for a high precision ball bearing. Credit: Excelleration
highlight of this material is its combination out of all
benefits. The smooth surface including the option of ▶ PA12
Wheel; Credit:
vibratory grinding with a 10 % lower density than PC-ABS Excelleration
makes this option highly attractive for the wheels. Lastly,
the low tolerance of ± 0.3 % eliminates the question of
regulation violation.

These are the results of the Wheel Stainless steel axis PA 12 printed axis Carbon fiber axis
integration tests conducted using
Material the testing device. All the following + High stability + Low weight + Relatively ow weight
+ Low tolerances - Lower stability + High stability
data are stated in kilogram. The ▶ The tested
- High weight - Uneven surface - Low tolerances
The choice of material for the manufacturing of the wheels is an Black letter represents the mass of prototype
- Partly not straight
wheels; Credit:
essential part considering the minimum weight, stability, and reaching the first point (5 mm Excelleration
surface finishing aspects. The following materials were available, limit), while the second point is Lastly, the carbon fiber axis were chosen for the final design. The 62
and using a throughout selecting process, some of these materials represented in the blue-green mm long axis only weigh 0,33 g using this material. Furthermore, the
were finished in the given form for integration tests. color. All the tested wheels were axis was cut precisely using circular saw
rear wheels with a height of 17 mm.

7
ADVANCED DC
 Finally, from the three available options of PTFE
spray produced by Weicon, Würth and WD-40,
Overview
Advanced Design Concept the option of WD-40 was selected. The main
After combining all results of design concepts, we evaluated the final
reason for this selection was mainly the surface
The advanced Design Concepts containing wheel system vehicle. This step was essential to do, before the manufacturing
quality after spray. Both sprays from Weicon and
and tether line guides, do not only include the CAD part, process, for a high compatibility of all parts.
Würth leave thin, white marks on the spot after
but more important, the material and real life test. The
application, while the WD-40 spray stays
results of these mentioned tests will then be presented in In the view of aerodynamics, the final design of the vehicle
transparent. The characteristic of heat
the following. improved by 19.18 % in comparison to the first designs, including the
resistance also promises the spray layer not to
wear off during the race due to the friction with first set of side pods, rear and front wings. The final vehicle delivers a
the tether line. drag force of 0.2903 N at the air speed of 22m/s.
▶ WD-40 specialist PTFE Spray;
Credit: Excelleration

Tether line guide

Wheel surface improvement
The material of the tether line guides play massive roles due to the
friction it potentially causes with the tether lines. Therefore, the After using PTFE spray for the tether line
results from Testing: Friction were used for exactly this purpose: guides, the idea of using it to reduce
friction in the wheel system also emerged.
Therefore, the surface of the wheels were ▶ Excellence 23-1 in simulation with layers and trails;
all applied with WD-40 PTFE spray after Credit: Excelleration
the polishing process from Rapidobject
before assembly. The additional weight ▶ The wheels applied with the The durability of the vehicle was constantly tested using the Solid
three different types of PTFE
was kept by around 0,07g to reduce the sprays;
Edge simulation and real life tests. With all the vulnerable parts of
impact on torque. Credit: Excelleration the vehicle being selected and tested separately on a significant
higher stress level than the real tests, we are confident, that all the
vehicles will survive the final impact at the target.
Ball bearings
The mass of the vehicle was also constantly measured during all the
Different types of ball bearings were selected to be tested and manufacturing and assembly processes. After using different light
evaluated to be finally used on the vehicle. The most influential weighted materials and weight reducing designs, the final racing
aspects here were the ease of movement and high maximum vehicles deliver a mass of 50,25g, which is only 0,05g off the initial
rotational velocity. All the tested ball bearings had small sizes of 2 target.
mm inside diameter and 5 mm outer diameter. As evaluated in
The torque of the wheels also improved in comparison to the first
Advanced DC

Research: Optimal rotation, the smallest rotational mass would be

most beneficial for the smallest amount of rotational energy. designs. The original design with PC-ABS would weight 2.19 g per
rear wheel, causing a torque of 1784,4 g·cm²/s², while the final design
using PA 12 only weighs 1,83 g per wheel, generating a torque of only
1456,52 g·cm²/s², reducing by 18.4%.

▶ Result of the friction test with different type of materials used in the Friction between the different parts of the vehicle and the track was
testing method listed in column diagram;
Credit: Excelleration
also strongly considered. By using the PTFE spray as an innovative
Reely plastic model MR 52 W2 solution, all the possible spots where the vehicle could cause friction
The result clearly shows, that the use of stainless + Low weight + Highest rotational velocity all covered up.
steel or ceramics guides are inferior to the choice + Low cost + High stability
of PTFE in the perspective of resistance. Here the - Extremely low stability + Highest ease of movement
PTFE - Low max. rotational velocity
choice is between a physical PTFE element and Element
PTFE spray.

In this case, the consideration of area of

resistance plays the significant role. The use of
PTFE
an additional PTFE element would mean, in Spray SSC MR63 W2 Flansch MF 52 W2
addition to a secure holding socket, the element
+ High rotational velocity + High stability
itself also cause additional area of resistance.
+ Low tolerances + Low tolerances
Calculation shows, the area of resistance of the - High mass - Not usable for the current
PTFE would be around 37.69 mm², while the use ▶ The difference in area - Lower stability than the rest of the wheel support system
between use of PTFE steel ball bearings
of PTFE spray would reduce the area to 18.85 element and spray in 2:1
▶ Rendering of Excellence 23-1
in ISO-perspective;
mm² (-49.9%). Moreover, the mass of the sprays resolution;
Credit: Excelleration
is also advantageous in comparison to the Credit: Excelleration Lastly, we selected the MR 52 W2 due to its characteristic of the
element. While only 0.05 g of spray are necessary highest rotational velocity and ease of movement. Options such as
per vehicle, the elements would weight an extra Flansch MF 52 W2 or Reely plastic model were abandoned due to
0.8 g per vehicle. their impracticalities.

8
ADVANCED DC

CNC/CAM
The manufacturing of the chassis was achieved by the
cooperation with the central manufacturing department of
the Helmut-Schmidt University (HSU) in Hamburg. There
were multiple necessary steps during the milling process
to achieve the desired precision.
CNC/CAM/Manufacturing
Workflow
A certain procedure is designed to secure a flawless manufacturing
using this cooperation. It starts with CAD and ends with the milled
vehicle.
1 600 U, TNC 430 Heidenhain ;
Firstly, the first prototype designs are being exported from
Solid Edge to STP. files. This is then imported into the used
CAM software MasterCAM 2023. Minor flaws in design can
be detected using the protocol tool and corrected back in
Solid Edge.
▶ MasterCAM with vehicle
designing milling strategy
; Credit: Excelleration
2
A milling strategy needs to be designed. Certain tools
need to be selected and a path for the milling head can be
automatically calculated by the program. Furthermore, it
needs to be considered which side of the vehicle needs to
be manufactured in which certain way.
In our case, the 3D HSC Hybrid function was selected as
an overall strategy. It combines both tools of shank cutters
and sphere cutter to achieve ultimate flexibility. Firstly, a 12
mm diameter shank cutter was used to remove the
biggest unnecessary part of the material. Furthermore,
more details were polished by using a 6 mm shank cutter.
For the smallest details, one 3 mm shank cutter, one 2
mm sphere cutter and one 6 mm sphere cutter were used
to define the smallest features of the vehicle such as the
inlet of the side pods. Here, the other side-strategies are
used, such as 3D dynamic OptiRest and 2D dynamic
3
contour.
The finished data is being exported and then delivered to
the mill. There the program is set up to be manufactured.
Furthermore, small adjustments need to be done by the
milling machine to determine if minimal corrections in
location are necessary.
Lastly, the manufactured models need to be
Product measured and weighed after tolerances to find
imperfections, see: Manufacturing: Quality Control.
Equipment Polyamide 12 was printed by Rapidobject, using the new technology
of HP, Multi Jet Fusion. This technology allows the PA 12 powder to
The milling machine used was the model C 600 U by the German
be hardened using infrared lights as energy source in connection
with two chemical solutions, the fusing and detailing agents. The
company Hermle. This five axis machine has a xyz-travel distance of advantage of this technology over conventional SLS procedures is
600 mm x 450 mm x 450 mm, which are all powered by electric firstly the higher surface quality and secondly the possibility of
motors. The spindle reaches a maximum rotational speed of 16000 shaper edges due to the modified energy source of infrared light,
rotations per minute. The highest resolution of this device lays by instead of conventional laser.
0,001 mm, which provides relatively high precision. The control panel
of the device is the model TNC 430 by Heidenhain.
Multiple milling heads are available on this machine. Ranging from 1
mm sphere cutter to 8 mm shanks cutters. As mentioned before, we
utilized different options to achieve the highest efficiency while still
Addition of powder Fusing/Detailing Infrared Light Attached PA 12
having high precision for details.
Agent
▶ Multi Jet Fusion procedure of PA 12; Credit: Excelleration
▶ Left: The Hermle C 600 U of HSU Furthermore, the high durability of the material with a yield stress of
with engineering drawing of the
chassis ; Credit: Excelleration > 46MPa and flexural strength of > 55MPa simply fulfilled all
necessary characteristics for the given parts. All parts where
▶ Right: The control panel of the C
confirmation were necessary, such as wheels or halo, were
Credit: Excelleration separately tested. But for the nose cone, rear wings, helmet and
wheel support systems, PA 12 was chosen to be the final
manufacturing material.
Attachment Quality control
One of the most important questions during the manufacturing The key of quality control is the
process is the attachment of the vehicle. A grave mistake would be achievement of low tolerances. This
the block being loosened during manufacturing. For that, it is also applies to all used parts during the
necessary to consider which side of the vehicle needs to be manufacturing process. After the
manufactured first. manufacturing process, the vehicles were
measured while compared with the
For the bottom side of the vehicle, the block was stuck using a engineering drawings. This process was
clamping device to achieve stability. But this was not possible for the repeated after the assembly process.
other side, due to damage which would occur on the body of the More than the two necessary vehicles
vehicle. For that, a solution was designed to firstly mill a counterpart were manufactured and assembled to
of the bottom half out of aluminum. The mill then processed this avoid the danger of wrong
part. Furthermore, the bottom part is inserted into the counterpart, measurements on one of these specific
which then can be stuck between using the clamping device. This vehicles. Then the best three of the
aluminum part can be used to be manufactured in the future, which vehicles are selected after surface quality
therefore produces no waste after the production. and accurate sizes. After all the necessary
painting process, vehicles are being
measured again with the consideration of
▶ Multiple vehicles being
▶ Left: The aluminum manufactured and prepared
counterpart being installed to mass. The most optimal ones (slightly for measurement sessions
the machine ; Credit:
over 50,2g) are being selected to be the Credit: Excelleration
Excelleration
final racing vehicles.
▶ Right: The vehicle being
inserted onto the counterpart ;
Credit: Excelleration The qualities considering wheels are being observed otherwise.
More than 30 wheels were manufactured for both front and rear
wheels.
Outsourcing
Firstly, the diameter of all wheels are being measured and noted.
All used parts on the vehicle were manufactured by our Secondly, the 15 best front and rear wheels are being selected and
manufacture supporter Rapidobject. The main reason for the installed with ball bearings. Furthermore, they are being tested
decision of outsourcing those parts was mainly the precision and using air accelerator to a rotation per minute of 10,000. This process
quality of the manufactured parts. The two 3D printers given in the is being conducted with all wheels multiple times. After evaluation,
school were Ultimaker 2+ and Ultimaker 3 from the Dutch the best 6 front and rear wheels are being installed to the three
company, powered by the software Cura. The printers were used to vehicles. These vehicles are then being measured again with special
print some wheel prototypes. But unfortunately, no matter which considerations on mass. The best of them are then being selected to
material or settings were tested on the Ultimakers, the self be the final racing vehicles.
manufactured final parts simply had worse tolerances than the
expectations (In 60% of the case ±0.7 mm)
9
CNC/CAM/MANUFACTURING
 Secondly, after assembly, a mixture of
polycrom filler and its hardener is applied
Assembly
Manufacturing to the surface of the vehicle in a thin film
High precision is necessary for the assembly of the vehicle to achieve
using a paint brush. This mixture is done in a
Manufacturing contains the final part of work after the the desired design, as in CAD. For this, different measures were
ratio of 50:1. This combination allows the filler
chassis of the vehicle is milled and all other necessary parts taken:
to harden in a relatively short amount of
are 3D-printed. The question range from the filling of the
time while not overreacting. After the drying
pores to work safety. The aim of this part of work are at Due to the small attachment area for the rear wings, a tool was
process of the fluid, the surface needs to be
least three fully manufactured vehicles. necessary to define the exact location, where the wings need to be
ground again using sand paper. But this
process does not represent an issue for placed. For that, the rear wing attachment tool was used during the
surface deformation due to the hardness of assembly process.
the dried resin. The mass of the applied
Manufacturing/Assembly

mixture also needs to be measured precisely ▶ Top: The used croma filler;
Furthermore, the assembly process was easier due to design
to prevent the vehicle to extend the desired Credit: Excelleration considerations in forehand, such as the socket on the front or the
fitting socket for the wheel support systems.
Safety measures mass of 50,2g. The 3D-printed parts such as ▶ Bottom: Application on the
nose cone or rear wings shall not be covered vehicles
Credit: Excelleration
Multiple measures were taken during the manufacturing and by the mixture, because of the chemical
assembly process to guarantee safety. Risk management was the characteristic of the filler, the fluid will not
main tool in preventing injuries or other issues. dry, if applied on smooth materials such ▶ Left: PA 12 Attachment
tool; Credit: Excelleration
Polyamide 12.
▶ Right: Socket design front
Credit: Excelleration
This process needs to be done repeatedly,
Imagine Calculate Evaluate until the surface does not show any more
irregularities.

Eyes injuries due to splash
from Polycrom Filler during
the painting process
Skin or lung irritation due to
sand paper or chemical
corrosion due to contact with
the glue or filler
Cuts or other serious skin
damages during the cutting
of the axis or removal of extra
material
Overall, injuries were unavailable due to the
throughout protection
Mediocre impact, low During the painting process,
probability
safety glasses needs to be
permanently worn
Low impact, high FFP 2 masks and hand shoes
needs to be worn, and
probability
permanent ventilation is also
necessary
Extremely high impact, low Special cutting and holding
probability
techniques ensure the body
parts to be secured
during the
The sand paper used in this process are all
containing over 500 grain units, which Painting
makes the paper overall rather smooth. This
process takes long due to the hardness of This year, self painting and professional airbrush were both options
the filler, but it reduces the risk of surface available for the painting process. The main considerations here
deformation due to unwanted removal.
were again the surface quality and the mass of the paint. Those
evaluations were made for the selection of method:
Before the painting process, another layer of primer is applied to the
vehicle over the entire body. This is used to make the future paint
stick more durably. This process is done professionally by our painter,
who uses the specific AK interactive primer to enable future ▶ Left: Self painted
prototype; Credit:
airbrush process. Next to the primer, a small amount of putty mass Excelleration
was also applied to some connection spots of the vehicle to produce
a smooth transition between the individual parts. This amount was ▶ Right: Airbrushed
Excellence 21-2
kept small to reduce weight imbalance on the vehicle. Credit: Excelleration

manufacturing stage. All utilized materials

or chemical substances were checked in Glue Self Paint Airbrush
forehand about possible hazard.
Furthermore, other emergency items such The glue used for the assembly also needs to be selected carefully in
+ Smooth surface + Smooth variable surface
+ Low expenses (€10 per can) + Extremely low additional mass (1g)
as first-aid kit or eye shower were prepared forehand to achieve an easy assembly, while still having maximum - Relatively high mass (3-5g) + Highly complicated designs available (Fade)
either to reduce possible further impacts. stability, those were some alternatives available: - Complicated designs not - High costs (€150 per vehicle)
possible

▶ Safety gears including safety glasses, FFP2 masks or hand Lastly, we decided to airbrush all our vehicles due to our
shoes;
Credit: Excelleration ▶ Left: UV Glue with the UV lamp; acquirement of complicated designs and low weight. Our close
Credit: Excelleration
cooperation with the airbrusher led to high final surface qualities.
▶ Right: Cyanacylat glue
Surface editing Credit: Excelleration The airbrush process started with a layer of basic white color, on
which the fade was applied to. The special water dissolvable stickers
A key characteristic of polyurethane foam is the porous surface after were then applied to the vehicle during this process. Finally, after the
the milling process. This characteristic was negative for the finishing UV Glue Cyanacrylate
color layers, one final layer of clear coat is applied to the entire
process afterward, such as painting. Therefore, the pores on the surface. Not to forget, during the painting process, some parts of the
surface need to be reduced. - High viscosity - Quick drying process wheel support system need to be covered off to prevent the invasion
- complicated application - Low viscosity
- Danger of accidental sticking - Easy application of paint in critical parts such as the connection to ball bearings.
Firstly, some basic sand paper grinding process was done to remove
visible milling trails, but no other surface changes are made in this Lastly, cyanacylate was selected to be used to assemble all parts to
case for minimal inaccuracy. the vehicle. The wheel support system benefited from the choice.
The low viscosity allowed the glue to quickly spread into smaller
spots, which would not be reached using highly viscous glues.
10
MANUFACTURING/ASSEMBLY