Hungarian student team SZEngine has produced the world’s first 3-D printed Formula Student racing engine.

All of the main components for the 55hp single-cylinder engine were produced using an SLM 280 additive-manufacturing system, working in co-operation with the Motor Manufacturing Centre (MAC) of Audi Hungaria in Győr.

SZEngine (www.szengine.hu) is a team of students that designs and develops racing engines for teams taking part in Formula Student (the international racing series in which students design, construct and then race their own cars).

The team has now succeeded in producing ‘a complete engine’ using selective laser melting on the SLM machine, which has a build envelope of 280 x 280 x 365mm.

As a pilot project, the team began by printing the timing side of the crankcase, but as the component had been designed for conventional processing (and therefore required too many support structures), they decided to digitally re-design it to make it suitable for 3-D printing.

However, in order to be able to call the engine a “3-D printed engine”, the team subsequently re-designed all of the other main engine components, producing nine engine components using SLM technology — the two-part crankcase, the cylinder, the cylinder head and cylinder head cover, as well as the covers for the clutch, timing belt, oil filter and oil pump.

Ralf Frohwerk, global head of business development at SLM Solutions, said: “Every day, our customers are placing greater trust in SLM technology.

“This impressive project from SZEngine and Audi Hungaria in Győr clearly shows that metal-based 3-D printing is not just suitable for prototypes but can also be successfully used for series production — especially small batches.

“Moreover, this customer’s experience in component design for 3-D printing shows how additive manufacturing can enable improvements both in terms of function and performance.”