Formula Student

For Formula Student, I was part of the Powertrain Team, working on the design and development of the car’s intake manifold. My contributions involved researching engine performance and applying Lotus Engine Simulation to determine key design parameters such as plenum volume, runner length, and diameter. I also helped design and model several intake manifold concepts using Fusion 360, ensuring compliance with IMechE rules, including those related to the surface envelope, throttle body, and restrictor.

Side view of the Yamaha MT-07 engine
Top view of the engine with the valve cover removed, revealing the camshaft, valve train, and timing chain system
Close-up view of the intake port on the cylinder head, illustrating the airflow path and sealing area for the intake manifold
CAD render of an intake manifold design
Alternative CAD render of an intake manifold design
Visual representation of intake manifold integrated with the vehicle chassis

Finalised manifold design optimised for airflow and engine compatibility:

Front view of finalised personal design
Rear view of finalised personal design
Front View of velocity streamlines from Ansys simulation, illustrating airflow distribution through the intake manifold 
Rear View of velocity streamlines from Ansys simulation, illustrating airflow distribution through the intake manifold 
Intake ANSYS Test 1.mp4
Video showing Front View Ansys simulation results for airflow velocity, highlighting design efficiency and flow uniformity 
Intake ANSYS Test 2.mp4
Video showing Rear View Ansys simulation results for airflow velocity, highlighting design efficiency and flow uniformity 

After completing flow simulations and performance tests using ANSYS Fluent, the team evaluated each design. One of my colleague’s designs was selected as the final intake manifold due to its superior performance in airflow optimisation. Following this decision, my colleague took responsibility for finalising the design and incorporating features such as mounting points and pressure sensors, as shown below.

Final Intake Manifold Design

With the intake manifold design completed, I shifted my focus to the manufacturing and fitting of the car’s muffler. This allowed me to contribute further to the Powertrain Team and gain valuable hands-on experience in the practical assembly and implementation of the car’s exhaust system.

A close-up view of the notching process, highlighting the accuracy required for proper assembly
Notching pipes at precise angles to ensure a perfect fit for the engine mounts and exhaust system on the chassis
Cutting the pipes to the required lengths and preparing them for notching and assembly
Welding components together as part of the exhaust system assembly
Grinding a welded section to smooth out edges and refine the finish of the muffler
Sandblasting the muffler to remove surface imperfections and prepare it for a smooth, uniform finish
Rear view of the completed vehicle showcasing the engine and intake manifold
Detailed rear angle of the car's drivetrain and exhaust integration
Created the firewall, as it is a safety-critical barrier designed to protect the driver from heat, fluids, and debris, in compliance with IMechE Formula Student regulations
The front nose of the car featuring the IMechE Formula Student sticker, which proudly displays the stages successfully passed during the competition
Final display of the car:

Certification:

Participating in the Formula Student competition was an enriching experience that allowed me to develop practical engineering skills and collaborate with a team on challenging automotive tasks. I am proud to have received a certificate recognising my involvement and efforts.