From Design to Reality: PCBWay Helps Nova Racing Bring Our Engineering to Life
Precision. Innovation. Performance.
TURNING IDEAS INTO PERFORMANCE
In Formula Student, every component on the car represents months of engineering, simulation and optimization. Designing innovative parts is only half of the challenge—the real test is transforming those designs into high-quality, reliable components capable of performing on track.
This season, Nova Racing Team partnered with PCBWay to manufacture several key components for our Formula Student prototype. Thanks to their advanced manufacturing technologies and outstanding production quality, we were able to turn some of our most demanding designs into reality.
THE COMPONENTS
INTAKE
The Intake is one of the most complex components on our car, designed to efficiently distribute airflow while meeting the packaging constraints of a Formula Student powertrain.
Manufactured by PCBWay using HP Multi Jet Fusion (MJF) in PA12 Nylon, this component combines lightweight construction with excellent dimensional accuracy and mechanical performance.
The freedom offered by additive manufacturing allowed us to design smooth transitions, integrated mounting features, and complex geometries that would be extremely difficult to manufacture using conventional methods.
INTAKE RUNNERS
Complementing the intake, PCBWay also manufactured the Intake Runners, which guide the airflow from the plenum towards each cylinder.
These components require high dimensional accuracy to ensure proper sealing and assembly while maintaining the designed airflow characteristics.
The excellent print quality provided by PCBWay allowed the runners to integrate seamlessly with the rest of the intake system.
COMPLETE INTAKE ASSEMBLY
Once assembled, the Complete Intake Assembly showcases the full potential of additive manufacturing for motorsport applications.
The combination of the intake body and runners results in a lightweight yet robust assembly capable of meeting the demanding requirements of Formula Student competition.
The final part accurately reflects our original CAD design while significantly simplifying manufacturing compared to traditional fabrication methods.
ACCELERATOR PEDAL
Precision and reliability are essential for every driver input, making the Accelerator Pedal one of the most critical driver interface components.
PCBWay manufactured this part using high-precision CNC machining, producing an exceptionally clean finish while preserving the lightweight geometry designed by our team.
Carefully machined pockets remove unnecessary material without compromising structural rigidity, resulting in a component that is both lightweight and highly resistant to deformation.
BRAKE PEDAL
The Brake Pedal demonstrates the advantages of metal additive manufacturing for highly optimized mechanical components.
Its organic geometry was specifically designed to maximize stiffness while minimizing weight, creating a structure that would be extremely challenging to manufacture using conventional machining.
Thanks to PCBWay’s manufacturing quality, the final component preserves every design detail while achieving the mechanical performance required for competition.
PEDAL PADS
To complete our pedal assembly, PCBWay also manufactured the Pedal Pads for the accelerator, brake, and clutch.
The lightweight honeycomb-inspired pattern improves driver grip while reducing unnecessary mass, maintaining both functionality and aesthetics.
The precise machining and high-quality finish perfectly complement the rest of the pedal box assembly.
Engineering Made Possible Through Collaboration
Formula Student is built on innovation, teamwork and strong technical partnerships.
Working with PCBWay has allowed Nova Racing Team to manufacture lightweight, precise and high-quality components that meet the demanding standards required for competition.
We are proud to have PCBWay supporting our team and look forward to seeing these components perform on track throughout the season.