Karolin Madsen

• Rethinking the body structure of formula car on the example of Formula Student team Tallinn
• Tutor: Ruth-Helene Melioranski

This master thesis examines 3D printed lattice structures in different fields: automotive, aviation and aerospace, medicine, architecture, and fashion, to find solutions in rethinking the body structure of Formula Student car. The problematic locations in the manufacturing of the car body are the curved surfaces where the installation of the aluminium honeycomb is very time-consuming.

The aim of the research is to offer 3D printed alternative solution to Formula Student team Tallinn formula car body manufacturing. Alternative parts need to take the shape of the car body mould while optimizing the mass and meeting the set requirements. Given thesis is purely studying the form formation of internal structures, not the outside form design, because it is assumed that the shape of the body of formula car is sufficiently optimised to meet the parameters required in competitions.

As a solution, five different lattice structure concept solutions were designed in Autodesk Inventor and 3D printed with SLS printer. Feedback on the concepts was received from the chief engineer in the Formula Student team.

The main goal of the solution is to offer more convenient and faster manufacturing method for Formula Student team Tallinn, simplifying the internal structure building process and enabling the team to perform vehicle tests earlier, while also being more competitive.