Each Formula Student car is the culmination of endless engineering hours, yet concepts from blueprints and CAD models truly come to life only with the backing of elite manufacturing partners. This season, Dalstroj has been one such partner, playing a pivotal role in our advancement. Renowned for their expertise in machining, Dalstrojis celebrated for tackling complex production challenges by blending state-of-the-art CNC turning and milling with seasoned experience. Their dedication to quality and precision makes them the perfect partner for motorsport projects, where micron-level tolerances are strict and reliability is non-negotiable.
The Team's First Planetary Gearbox
Creating our very first planetary gearbox represented the season’s most significant engineering challenge, and Dalstroja expertise was instrumental in making it happen. With high-stress loads in the powertrain, we engineered the gears and shafts from 42CrMo4alloy steel. Chosen for its superior yield strength and fatigue resistance, this material was machined by Dalstroj using high-precision CNC turning and milling to hit every single tolerance. To maintain a lightweight design, the gearbox covers were crafted from 7075-T6 aluminum—an alloy offering the strength of steel at a fraction of the weight..
Complete Suspension Overhaul
Aside from the drivetrain, Dalstroj played a crucial role in crafting key suspension components—an area where precision and material integrity are matters of driver safety. We adopted a hybrid approach for the suspension arms , mating carbon fiber tubes with high-precision inserts made from 6082-T6 aluminum,an alloy chosen for its blend of machinability and bonding capabilities. Simultaneously, the wheel hubs which withstand extreme lateral loads in corners—were crafted from 7075-T6 aluminum. This high-end machining enabled us to cut down on unsprung mass, resulting in sharper vehicle handling.
Partnering with Dalstroj showed us the value of working with a manufacturer who brings both equipment and a passion for engineering to the table. Their quality allowed us to test the limits of our design, confident in every single micrometer of the material. A huge thank you to Dalstroj for joining our journey and boosting our car's performance with their machining skills. We can’t wait for future projects together!
