In August 2023, DIAN Racing set out for the 2023 FSAEJ Japan competition. The latest DRe23 car achieved 3rd place in the Design Event, 1st place for the Best CAE Award, 2nd place for the Best MathWorks Award, 2nd place for the Best Aerodynamics Award, and 3rd place for the Best Ergonomics Award.
The DRe23 formula car has been upgraded in its electrical systems, wheel assemblies, aerodynamics package, bodywork, and ergonomics, fully showcasing the car’s traits of being “lighter,” “faster,” and “more stable.”
Lightweighting is crucial for improving the speed and performance of formula cars. Metal 3D printing technology offers significant advantages in achieving structural lightweighting. In 2021, DIAN Racing partnered with BLT to prepare for the Formula Student China competition. Innovation and breakthroughs are core values at BLT, aligning perfectly with DIAN Racing’s persistent innovative design philosophy.
DIAN Racing team members optimized designs for lightweighting, space utilization, and aerodynamic performance. The DRe23 car’s uprights, rocker arms, flanged ears, and other parts were created using generative design methods, employing AI tools to calculate the optimal structure under given loads and constraints. The BLT-S400 equipment enables batch production of these parts. Taking the uprights as an example: each upright has a height of 118 mm, with a full build plate capable of forming four pieces in just 57.2 hours. The finished parts exhibit excellent consistency, meeting strength and stiffness requirements. Moreover, the parts achieve maximum lightweighting; the four uprights are 24% lighter than those on DRe21.
Parts printed by BLT for DIAN Racing
In addition, BLT also printed parts such as the water-cooling housings for the team. The internal channel structure of the DRe23 water-cooling housing is very complex, making traditional manufacturing methods difficult. 3D printing technology enables integrated forming of the channels, optimizing the motor’s heat dissipation performance.
Material lightweighting is also an important approach for formula car lightweighting. BLT selected high-strength aluminum alloy material, which has low density and high strength, reducing weight while ensuring part strength.
“BLT has provided DIAN Racing with substantial technical support, helping DRe23 achieve performance breakthroughs. It is a close partner of DIAN Racing, and the team hopes to continue strengthening cooperation in the future to achieve new breakthroughs in formula racing,” commented a DIAN Racing team member.
BLT will continue to advance its technology and provide more high-quality products and services to the team. We also wish DIAN Racing even greater success in future competitions, dominating the track.
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