Case study

3D printed prototype of a steering knuckle


AGH Racing – Student research group (at the AGH University of Science and Technology in Kraków) constructing Formula Student racing cars.

3D printing in a company

New technological solutions seem to be a natural environment for the construction of racing cars. By using 3D printing technology, students were able to create innovative solutions for their vehicles and, as a result, achieve better results in competitions. The possibility of producing from a wide range of materials, including ABS, PEEK or reinforced materials such as PA-CF allowed this research group to create mechanically durable details that can be used in their race cars.


3D printout was used to examine the design topology of the steering knuckle. The project was developed to reduce the weight and increase the stiffness of the element.


1. Creating a prototype to verify the design at lower costs

Usually, the knuckles are being made of aluminum by milling. The introduction of significant changes in the geometry of the part makes it impossible for such a complex shape to be subjected to conventional machining. In order to verify the project, without big financial investment, FDM technology was chosen.

The 3D printed steering knuckle helped to verify the project’s assumptions before forming the model itself and avoid costly improvements in other technology (printing in SLS technology reached up to 20,000 €).

2. Reducing the time of prototyping

Due to the FSAE race in Michigan, AGH Racing had to make a prototype of the new model of steering knuckle in a very short time. 3D printing in FDM technology allowed to receive a prototype much faster. The use of soluble ESM-10 solution as a support material allowed for efficient post-processing of the model. SLS prototyping would take too long.

Thanks to the 3DGence INDUSTRY F340 a prototype was 3D printed in less than 2 days. This time reduction allowed students to present new details to the judges.

Model of steering knuckle in 3DGence Slicer 4.0 software.
Steering knuckle was 3D printed with ABS (model material) and ESM-10 (soluble support material).

Products we used