Additive Manufacturing for Chalmers Formula Student

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Presentation of the 2024 car.
Production of one of the AM parts in the machine
AM produced wheel spindles, with close-up
Metal parts produced with additive manufacturing
Metal parts produced with additive manufacturing.
Presentation of the 2024 car.
The Chalmers Formula Student car of 2024.

CAM² is one of the sponsors of Chalmers Formula Student, the project where 50 students spend a year designing and building an open-wheel racing car, to compete against teams from technical universities from all over the world.

In the 2024 edition of Chalmers Formula Student, CAM2 and the powder supplier Höganäs AB collaborated to produce metal parts for the car using additive manufacturing, where CAM2 also provided infrastructure and resources for printing.

The components produced are wheel spindles and triangles that are part of the wheel suspension. They were printed using the newly developed high strength aluminium alloy called forAM Al-HS1. Another part produced was brake calipers, printed using the cobalt free maraging steel forAM TS-CF1.

Using additive manufacturing for these parts of the car offers advantages such as faster production, enables the creation of complex geometries, and provides increased design flexibility for topology optimization. The 3D models for the parts have been designed by the students involved in Chalmers Formula Student and further prepared and printed by the engineers at Höganäs AB.

"We are very happy with the collaboration we have had with CAM2 and Höganäs. We have received very nice prints, and hope that we can continue the collaboration in the future," says Gillian Makrof-Johansson, part of the Suspension Team in Chalmers Formula Student.

Engineers: Dmitri Riabov, André Larsson and Sven Bengtsson, Höganäs AB

Student: Gillian Makrof-Johansson, Chalmers Formula Student

More about Chalmers Formula Student

Chalmers Formula Student bridges the gap between Engineering Education and Industry by training students in a real-life project where they independently Design, Analyze and develop Technology solutions by making Data-Driven Decisions throughout the Design, Manufacturing and Testing of a full-fledged Formula Racing automobile, and finally put their skills to the test in competitions with various other teams from the rest of the world.

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