Case Study: Oregon State University achieves a lightweight, high-performance SLS intake system with 3D Systems

University Race Team Benefits from SLS Engine System

3D Systems partnered with the Oregon State University Formula SAE team to address the team’s time-consuming, hand-built intake systems, which produced inconsistent geometries and subpar performance. The challenge was to create a reliable, competition-ready intake that met SAE rules while improving engine breathing and manufacturability.

Using its Rapid Manufacturing Center and Selective Laser Sintering (SLS) with tough DuraForm PA plastic, 3D Systems produced three complete intake assemblies directly from the team’s CAD, iterated via Quickparts, and delivered a lightweight, regulation-compliant design. The SLS intake improved cold starts, fuel and air efficiency, and on-track consistency—earning praise from judges and peers—and helped the team place 10th in Design, 4th in Acceleration and Skidpad, and 22nd overall despite later mechanical failures.

Oregon State University

Jonathan Brad

Oregon State University