Propelling the Beavers: Global Formula Racing Fuel Tank
Propelling the Beavers with SLS 3D Printing
OSU Global Formula Racing Fuel Tank
We love showing our Oregon school spirit. Whether you root for the Beavers or the Ducks, collaborating with local university students is always a blast.
The Bottleneck: Squeezing Big Performance into Tight Spaces
Oregon State University students in the Global Formula Racing, Formula Student Program needed a custom Formula Racing fuel tank for upcoming competitions in Austria and Germany. They required lightweight automotive parts with complex geometries to fit inside a notoriously cramped chassis. Traditional manufacturing simply wasn't going to cut it. The racing team chose additive manufacturing, specifically Selective Laser Sintering (SLS), because it delivers the uniform strength, chemical resistance, and intricate internal baffles required for brutal track conditions. We tackled this rapid prototyping project using durable PA 2201 Nylon 12 and a tough liquid tank sealant. From the initial design handoff to the finished product, the entire process took just three months.
The Solution: Teaming Up for a Flawless Print
You rarely print a complex CAD file perfectly on the very first try. The students' initial 3D printed fuel tank design had a few structural hiccups. We brought in Tim Klein, an engineer at Northwest UAV and a proud OSU alumnus, to help refine the model. Tim knows his way around custom fuel systems. Channelling his inner Beaver, he collaborated directly with the students. Together, they tweaked the geometry for successful SLS 3D printing, ensuring the final tank would be completely track-ready.
The Results: Crossing the Finish Line
The custom SLS 3D printed fuel tank performed flawlessly. The OSU team raced fiercely at both Global Formula Racing events, backed by reliable, high-performance additive manufacturing. We are incredibly proud of their hard work and thrilled we could play a pit-crew role in their racing journey.
Need a rapid prototyping solution for your next demanding project? Contact us today, request a quote, and upload your 3D CAD files to get started!