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AUDI A1 MHCE | INNOVATION

Additive Manufacturing Applied

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Rear Wing 

The rear wing was made using FDM 3D printing using PETG. The wing was reinforced with aluminium supports and bolts directly to the existing chassis. Producing 2000N of downforce at 200km/h

Intake System 

A custom air intake system made from carbon fibre nylon was made to increase airflow also using a power filter and thereby increase engine performance in combination with an external boost enhancement chip. 

Front Canards 

In order to get a better aero balance of the car given the rear wing a set of 4 canards were designed using a laser scanner and printed using PETG. However realistically this adds mainly to the car's aesthetics. 

Shifter Paddles  

The stock shifter paddles on a range of Audi models are notoriously small and difficult to operate. Using CA12 + 5CF carbon fibre nylon new more optimised paddles were made which are more user friendly

WING

The design and development of the wing for the Audi A1 was a complex task especially given limited resources and no access to 3D scanning technology. The wing was developed and tested over the span of 2 months. The result can be seen on the right. 

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INTAKE

A custom air intake system made from carbon fibre nylon was developed to increase airflow. The design is highly innovative for 3 reasons:

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  • The employment of additive layer manufacturing which allows for a double wall design which insulates the intake air from the engine temperature just like a thermal cup

  • The use of the Venturi effect within the intake to accelerate intake air and thereby create more suction as well as turbulent air beneficial to the performance of the air filter

  • The integration of internal fins which guides the air into 3 channels allow the more remote sections of the system to provide more airflow to the air filter 

CANARDS

In order to get a better aero balance of the car given the rear wing a set of 4 canards were designed using a laser scanner and printed using PETG. However realistically this adds mainly to the car's aesthetics. 

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SHIFTER 
PADDLES

The stock shifter paddles on a range of Audi models are notoriously small and difficult to operate. Using CA12 + 5CF carbon fibre nylon new more optimised paddles were made which are more user friendly

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