Additive Manufacturing for Racing Car Development

This case study outlines how the University of Southern California's Formula SAE team, USC Racing, addressed challenges in building high-performance race cars through the adoption of additive manufacturing. Traditional manufacturing methods posed limitations due to the complexity and cost of aerodynamic components, tight timelines, and resource constraints. To enhance their design and build process, USC Racing partnered with Stratasys, utilizing 3D printing technology to produce over 100 components that improved aerodynamics and boosted downforce significantly. The implementation of custom jigs and fixtures reduced frame welding time and allowed for in-house fabrication of titanium components. Additionally, the team developed lightweight and durable parts, such as dashboards and heat shields, which expedited fabrication timelines. Their innovative approach led to a notable achievement, securing a podium finish at the FSAE Michigan International Speedway, where they placed 3rd out of 120 teams. This success exemplifies the impact of modern manufacturing techniques on engineering education and competitive performance.