ANUFS Flow-Optimised Intake Manifold

Founded in 2006 and rejuvenated in 2020, the ANU Formula Sport team is composed of more than 30 students from The Australian National University in Canberra. Each year, the team designs, builds, and races a Formula Student car to compete in international Formula SAE competitions. Our team is made of passionate students from diverse fields, including engineering, physics, and computer science, united by a commitment to innovation and high-performance design. After the original team was disbanded back in 2006, a group of dedicated and driven students revived the team in 2020 and started working towards being able to compete again. After spending some years working on logistics, design and manufature, we were able to compete for the first time in the FSAE-A 2024 competition with our first edition naturally aspirated engine car, and not only did we compete but we we able to come away with first place in both the Cost and Acceleration events in the IC category, as well as receiving the Aspiring Motorsport Award for best team spirit.

Buding on the success of last year, we're building an entirely new car and aim to compete in the 2025 competition in December this year. For this, we've developed some key improvements to the design, including an entirely new chassis, a full aero package, a new pedal system and a custome air intake to support a potential turbocharged air system. As such, we've partenered with some of our members for their major Honours thesis projects to make great improvements to our design. One of the current projects, the air intake plenum optimisation, is a core development for the team’s entry in this year’s Formula SAE-Australasia competition. The plenum plays a critical role in the engine’s performance, affecting airflow, volumetric efficiency, and ultimately the car’s power output and performance. The team has achieved significant success in past competitions, consistently improving vehicle performance and design, and is now aiming to integrate advanced manufacturing technologies to push their capabilities further.

A central aspect of this project is the use of Selective Laser Melting (SLM) 3D printing to manufacture the intake manifold. Traditional fabrication techniques limit the complexity of internal geometries, whereas SLM allows for intricate, generative-design-inspired shapes that optimise airflow while reducing weight. This approach directly aligns with the team’s goals of innovation, performance, and preparing students for the future of engineering.

The intake system project is divided into two key components:

1. Structural and Flow Optimisation
2. Using CFD-based generative design, the team has developed plenum geometries that maximise uniform air distribution across cylinders while maintaining lightweight structural integrity. These designs often cannot be realised through subtractive manufacturing, making SLM 3D printing the enabling technology.
3. Integration and Testing
4. The printed plenum will be integrated into the Formula SAE car’s engine system, where it will undergo rigorous testing for durability, performance, and reliability under competition conditions. This provides invaluable hands-on experience for students in both design validation and advanced manufacturing processes.

The ANU Formula Sport team would greatly benefit from the support of PCBWay. As a student-led project working under strict timelines and budgets, the team faces challenges in accessing advanced fabrication technologies. Access to SLM capabilities would enable rapid prototyping, faster design iteration, and more ambitious engineering solutions.

The intended purpose of this project is to produce the flow optimised intake plenum shown in the images. After prototyping and testing a physical model using plastic, we're ready to build and put this new plenum into place on our competition vehicle. However, as students, we have little previous experience working with additive manuacturing technologies, which is why we'd love to partner with PCBWay to make this the best possible product we can. With your support we'll be able to not only produce this plenum, which is a unique method of design that hasn't been used in automotive design yet, but it will help to validate this new design method as a potential avenue for further development in the industry.

This support would empower students to engage with cutting-edge manufacturing methods, equipping them with the skills and experience needed to contribute to the future of motorsport and engineering industries. Together, we can build a stronger, more innovative Formula SAE team and inspire the next generation of engineers.