In this year’s Formula Student China 2020, DIAN Racing team selected ROHACELL® ultra-lightweight foam for the bodywork. As for the components, young racers boldly attempted to use 3D printing technology and flame-retardant polyamide 12 of Evonik to manufacture the battery module frame, controller housing structure, etc. 3D-printing technology is more applicable to manufacture complex structures and effectively reduce car weight, cycle times and costs.
Evonik timely responded to the team’s demands. With its high strength, excellent flame resistance and high processing precision, INFINAM® PA 6004 P was the best choice to produce components like battery cells, electric-controlling system, body aerodynamic kit, cooling system, etc. For example, with the 3D-printing technology, the module frame achieved an overall weight reduction of 1,000 grams and met flame resistance with a V0 rating to better protect the cells. The hollow keel reduced weight by 15% compared to traditional parts of the same location, while maintaining good mechanical performance and fatigue resistance. Meanwhile, the front compartment of the battery box accomplished a complex layout structure with good flame resistance and mechanical performance.
“Evonik has a long history of cooperation with DIAN Racing,” said Fuchao Hong, director of Performance Materials, “The team has adopted ROHACELL® core materials into the race car bodies in previous competitions. This year, I am glad to see the students opted for 3D-printing technology. Their excellent performance showcases the many advantages of additive manufacturing in automotive applications, including aspects of manufacturing efficiency, lightweight design and performance optimization. Going forward, we expect to establish an even closer cooperation with the team to explore the many possibilities of the material applications.”