Design and manufacture of a Formula SAE intake system using fused deposition modeling and fiber-reinforced composite materials

Purpose - The purpose of this paper is to discuss the design and manufacture of an intake system for a 600cc Formula Society of Automotive Engineers engine. Owing to the inherent geometric limitations imposed by the existing manufacturing process (bending and welding of aluminum), it is difficult to design and fabricate an intake manifold system in which pressure losses are kept to a minimum and equal charge is provided to each cylinder. The aim is to develop a fabrication process that circumvents these limitations. Design/methodology/approach - Fused deposition modeling (FDM) is used to create an intake system (consisting of a plenum, plenum elbow, and cylinder runners) that is then later covered in layers of carbon fiber composite fabric through vacuum bagging. FDM allows for geometric design freedom, while the layup of a composite material (and its associated high-temperature resin) provide the strength and heat-resistivity necessary for this application. Findings - As a result of this approach, a functional intake manifold is created that survived the high temperatures and pressures of the turbo-charged engine. The process allowed the geometry of the intake to be redesigned, resulting in reduced weight (due to lower material density and lack of welds, hose clamps, and silicon couples), improved charge distribution, and increased torque through a wide RPM range when compared to its traditionally manufactured aluminum counterpart. Practical implications - The approach described in this paper shows that a functional, end-use intake manifold can be produced by the combination of FDM method and subsequent lamination of a carbon-fiber composite material. The approach enables the geometric freedom to improve manifold design, resulting in improved vehicle performance. Originality/value - This case study presents a low-cost manner of directly manufacturing functional parts through the combination of FDM and composite material layup.