2017 Formula SAE Intake Manifold

I utilized my previous experience with the 2016 intake to optimize th design. I created an Excel spreadsheet with macros to analyze head loss. The two main drawbacks of the previous design were weight and the internal surface finish so I decided to use carbon fiber and focus on our mold preparation techniques. A male mold was created from 3D-printed ABS to ensure proper geometry and was finished with Bondo and finishing primer. The finished intake reduced weight from the previous design by 7.5 pounds and increased peak horsepower by over 10%.

Top — SolidWorks model final render of 2017 UTSA Formula SAE intake manifold. Bottom Left — Final male mold made of interconnecting 3D-printed ABS pieces. Bottom Right — First lay-up of carbon fiber on male mold.