Additive Intake Manifold

Following the failure of a welded aluminum intake manifold, I led the design and manufacturing of a new intake system for a 650 cc Formula Student race car. The intake geometry was developed using Helmholtz resonance principles to optimize overall size, runner length, and flow characteristics.

Additive manufacturing was selected to enable a curved, high-flow design. Although the intake was initially intended for SLS printing, supply-chain constraints required a transition to an FDM process. A low-cost PLA prototype was produced first to verify fitment and packaging before final fabrication.

The final manifold was printed in PPA-CF, a high-performance carbon-fiber-reinforced nylon, to improve strength, thermal stability, and durability. A sacrificial burst plate was incorporated into the lower section of the manifold to safely relieve pressure during an engine backfire and protect the manifold.

The design also features interchangeable intake bell mouths, allowing the engine’s power characteristics to be tuned by adjusting inlet length and diameter. Full performance testing is scheduled for early spring 2026 when dynamometer access becomes available; however, preliminary vacuum testing has shown promising results, with the manifold maintaining full vacuum over sustained periods.