How composites are advancing vehicle design through manufacturer-academia collaborations

Theory without practical knowledge is futile, and without hands-on experience, engineering students are unprepared for their future careers. Industry partnerships play a critical role in equipping these future engineers with the practical skills and experiences necessary to succeed. Here, Roberto Oppio, account manager at pull-wound composites manufacturer Exel Composites, explores how Exel Composites’ collaboration with the University of Perugia (UniPG) Formula Student team in Italy supports engineering education.

Formula Student is an international engineering competition where university teams design, build and race single-seater cars. Originating in the US as Formula SAE, it has evolved into a global event that evaluates students’ abilities in engineering, project management and business. UniPG participates in these holistic competitions biannually, gaining invaluable hands-on experience. The event requires teams to not only focus on vehicle performance but also to consider their car’s economic efficiency and market viability, preparing students for real-world engineering challenges.

The collaboration between the UniPG racing team and Exel Composites began when the student team sought to integrate Exel’s pull-wound carbon fibre technology into its vehicle designs. This partnership facilitated the application of Exel’s expertise in composite solutions to the Formula Student projects undertaken by UniPG, illustrating a mutual commitment to advancing engineering education and practice.

The results of carbon fibre

Every gram counts in motorsport, and reducing weight enhances vehicle acceleration, cornering agility and energy efficiency on the track, contributing to faster lap times and increased competitiveness. The potential adoption of carbon fibre in other vehicle components, such as aerodynamic flaps or a carbon fibre monocoque body, holds promise for further weight savings and performance improvements.

In comparison to commonly used automotive materials like aluminium or steel, carbon fibre offers a remarkable strength-to-weight ratio. Carbon fibre can have tensile strength up to 3 times greater than that of aluminium and nearly double that of steel. Additionally, carbon fibre’s density stands at ~1.55 g cc^-1, significantly lower than the 2.7 g cc^-1 of aluminium and 7.85 g cc^-1 for steel, contributing to overall weight reduction and improved vehicle performance. These factors make carbon fibre the ideal choice for critical parts, such as the steering system and suspension arms, which experience increased torsional stress.

The integration of Exel’s pull-wound carbon fibre tubes has led to remarkable improvements in the UniPG Formula Student vehicles, notably in weight reduction. The team’s first car, constructed with steel components, weighed a substantial 280 kg. However, after adopting Exel’s carbon fibre tubes, the team has set a target weight of just 245 kg for its newest car, representing a significant reduction in vehicle mass despite still using a space frame steel chassis.

Impact on education and industry success

Exel’s partnership with UniPG goes beyond enhancing the race car; it provides students with practical experience in using advanced materials like carbon fibre in real-world engineering situations. This hands-on application of theoretical knowledge prepares students for future careers by equipping them with essential engineering skills.

“Working with Exel’s carbon fibre technology has been instrumental in helping us improve our skills and grow not only as technicians and engineers but also as individuals, learning to work in a team and share both victories and losses,” explained Marco Righi, lead student for chassis and dynamics.

Through initiatives like this, Exel Composites not only supports educational development but also ensures a steady pipeline of skilled talent for the industry. The composites manufacturer has contributed to several projects of this nature, including their work with Politecnico di Milano’s Formula Student team, reinforcing its commitment to nurturing future engineers.

In bridging theory with practical applications, collaborations between industry players and academic institutions have become increasingly important. These partnerships, such as that between the University of Perugia Formula Student team and Exel Composites, show the vital role that collaborations play in shaping the engineers of tomorrow.

About Exel Composites

Exel Composites is one of the largest manufacturers of pultruded and pull-wound composite profiles and tubes and a pultrusion technology forerunner in the global composite market. Its forward-thinking composite solutions made with continuous manufacturing technologies serve customers in a wide range of industries around the world. Exel Composites’ products are used in applications in diverse industrial sectors such as wind power, transportation and building & infrastructure.

The company’s R&D expertise, collaborative approach and global footprint set it apart from the competition. Its composite solutions help customers save resources, reduce products’ weight, improve performance and energy efficiency, and decrease total lifetime costs. The company wants to be the first choice for sustainable composite solutions globally.

Headquartered in Finland, Exel Composites employs over 600 forward-thinking professionals around the world and is listed on Nasdaq Helsinki.

Cover photo : UniPG Racing team