Professional Class represents the pinnacle of student engineering in STEM Racing. While Developmental Class uses 3D printing for rapid learning, Professional Class demands real-world aerospace manufacturing techniques used by Formula 1 teams.
Machine a race car body from solid foam blocks with tolerances tighter than a human hair, achieving aerodynamic surfaces that would be impossible with 3D printing.
Learn CAM programming, multi-axis CNC operation, and precision measurement — skills used in aerospace, automotive, and advanced manufacturing industries worldwide.
The techniques we use mirror those in Formula 1 wind tunnel models, aerospace prototyping, and medical device manufacturing. Students gain hands-on experience with industrial-grade CAM software, G-code programming, and quality control methodologies used by professional engineers.
Foundation Phase
Primary Method
3D Printing (FDM/SLA)
Process
Two-side CNC if used (left/right machining only)
Focus
Learning fundamentals, rapid iteration, basic aerodynamics
Complexity
Simple geometries visible from side view
Master CAD fundamentals, understand basic aerodynamics, learn design-to-manufacturing workflow. Emphasis on rapid iteration - print, test, redesign, repeat. Build foundational skills before tackling Professional Class complexity.
FDM/SLA 3D printers are widely available in schools and makerspaces. Low material cost (PLA ~¥2,000/kg) enables experimentation. Overnight print times allow weekly design iterations throughout the school year.
Two-side CNC machining (if used) limits designs to extruded profiles - what you see from the side is what you get. No undercuts or complex 3D surfaces. Teaches students to maximize performance within constraints.
Championship Phase
Primary Method
Multi-Axis CNC Machining
Process
Top/bottom/side machining from model block
Focus
Real-world aerospace engineering, competition performance
Complexity
Complex undercuts, intricate aerodynamic features, extreme precision
CAM programming, G-code generation, multi-axis machining strategies, precision measurement, quality control. These are the exact skills used in Formula 1 wind tunnel model shops, aerospace prototyping facilities, and advanced manufacturing industries.
Industrial CNC mills with 4-axis capability, CAM software licenses, polyurethane foam model blocks, precision measurement tools. Higher investment in equipment and materials, but produces competition-winning aerodynamic performance.
Multi-axis machining unlocks true 3D aerodynamic optimization. Create flowing undercuts, venturi tunnels, complex surface blending, and features impossible with 3D printing. Design freedom limited only by tool access and material properties.
From CAD model to championship-ready car in 4 precision steps:
Creating precision 3D models in Autodesk Fusion 360 with parametric design principles. Every curve, surface, and dimension is optimized for aerodynamic performance. We use Computational Fluid Dynamics (CFD) simulations to test hundreds of design iterations virtually before committing to physical manufacturing.
Parametric modeling allows rapid design iteration and optimization
CFD analysis reveals airflow patterns, pressure zones, and drag coefficients
Virtual wind tunnel testing saves time and material costs
Design validation ensures manufacturability before CNC programming
Converting CAD models into machine-readable G-code using advanced CAM software like Fusion 360 Manufacturing or Mastercam. We define multi-axis toolpaths, select cutting tools, set feed rates, and simulate the entire machining process to prevent collisions and ensure optimal surface finish.
Multi-axis toolpath strategies enable complex undercut geometries
Adaptive clearing reduces machining time while protecting tool life
Finishing passes with ball-end mills achieve smooth aerodynamic surfaces
G-code simulation catches errors before the first cut is made
Machining the car body from high-density polyurethane foam model blocks using 3-axis or 4-axis CNC mills. The process involves roughing operations to remove bulk material, semi-finishing to approach final dimensions, and finishing passes to achieve the required surface quality. Top, bottom, and side machining enables intricate aerodynamic features.
High-density polyurethane foam provides excellent machinability and stability
4-axis rotary machining accesses complex undercuts impossible with 3-axis
Roughing, semi-finishing, and finishing strategies balance speed and quality
Tool selection (ball-end, flat-end, tapered) optimizes surface finish
After machining, the car body undergoes meticulous post-processing. Hand sanding with progressively finer grits (80→150→220→320) removes tool marks. Primer seals the foam surface and reveals imperfections. Final sanding to 400-600 grit achieves Ra 1.6μm surface finish (ultra-smooth). Precision measurement with digital calipers and CMM verification ensures regulatory compliance.
Progressive sanding removes machining marks while maintaining geometry
Automotive primer fills micro-voids and creates uniform surface for paint
Final paint finish reduces skin friction drag by up to 15%
CMM (Coordinate Measuring Machine) verifies ±0.01mm tolerances
Weight verification ensures 65g maximum (including wheels)
Professional-grade tools for world-class results:
Specifications
3-4 axis machining, ±0.01mm tolerance, model block cutting
Applications
Main body from polyurethane foam, complex undercuts, aerodynamic surfaces
Technical Details
Industrial CNC mills with rotary 4th axis enable complex geometries unreachable by 3-axis machines. Equipped with automatic tool changers, spindle speeds up to 24,000 RPM, and precision ball screws for repeatable accuracy. The 4th axis rotates the workpiece, allowing the cutting tool to access undercuts and create flowing aerodynamic shapes that would require impossible tool angles on a 3-axis machine.
Specifications
PLA/ABS materials, 0.1mm layer resolution, rapid prototyping
Applications
Full developmental cars, wings, wheels, airfoils, hybrid components
Technical Details
Fused Deposition Modeling (FDM) and Stereolithography (SLA) printers enable rapid iteration for Developmental Class teams. FDM uses thermoplastic filaments (PLA, ABS, PETG) melted and deposited layer-by-layer. SLA uses UV lasers to cure liquid resin into solid parts with superior surface finish. Both technologies allow overnight production of full car bodies, making them ideal for learning fundamentals before advancing to Professional Class CNC machining.
Specifications
High strength-to-weight ratio, aerospace-grade layup
Applications
Wings, structural reinforcement, weight optimization components
Technical Details
Carbon fiber reinforced polymer (CFRP) composites offer exceptional stiffness-to-weight ratios - stronger than steel at a fraction of the weight. We use pre-preg (pre-impregnated) carbon fiber sheets or wet layup techniques with epoxy resin. Layup orientation (0°, 45°, 90°) controls strength directionality. Vacuum bagging removes air voids and ensures consistent resin-to-fiber ratios. Used extensively in wings, endplates, and structural components where weight savings directly improve acceleration.
Specifications
Autodesk Fusion 360, Mastercam, SolidWorks integration
Applications
3D modeling, CFD simulation, CAM toolpath programming, G-code generation
Technical Details
Fusion 360 combines parametric CAD modeling, integrated CFD analysis, and CAM programming in one platform. Students learn to create associative designs where changes propagate automatically. The CAM workspace converts 3D models into CNC toolpaths with strategies like adaptive clearing, parallel finishing, and scallop control. G-code simulation visualizes the entire machining process before running the machine, preventing costly crashes and material waste.
Specifications
Digital calipers, CMM (Coordinate Measuring Machine), micrometers
Applications
Tolerance verification, quality control, regulation compliance
Technical Details
Quality control is critical in Professional Class competition. Digital calipers measure external dimensions to 0.01mm resolution. Micrometers verify wall thickness and critical features to 0.001mm. CMMs use touch probes to capture 3D point clouds, comparing manufactured parts against original CAD models. Optical comparators project magnified part silhouettes for profile inspection. These tools ensure compliance with competition regulations: 65g weight maximum, 250mm length limit, and aerodynamic legality.
Specifications
Orbital sanders, spray guns, curing ovens, ventilation systems
Applications
Surface preparation, primer application, paint finishing, professional-grade aesthetics
Technical Details
After CNC machining, surface finishing transforms raw foam into championship-ready bodies. Orbital sanders with dust extraction provide consistent, controlled material removal. HVLP (High Volume Low Pressure) spray guns atomize primer and paint for smooth, even coats. Automotive primers seal foam and fill microscopic voids. Final clear coat protects the finish and can reduce drag by creating ultra-smooth surfaces (Ra 1.6μm or better). Proper ventilation and PPE ensure safe handling of finishing chemicals.
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