Achieving rapid success with sustainable moulding tools
Tu Chemnitz Racing Team
Tu Chemnitz Racing Team
Tu Chemnitz Racing Team
The success of a student racing team can impressively demonstrate how practical innovations from research are. In the 2025 season, the project team from the DLR Institute of Lightweight Structures and the TU Chemnitz Racing Team (TUC Racing) worked closely together on the production of fibre composite components for a racing car. This collaboration has two objectives: manufacturing using sustainable moulding tools and testing the manufacturing processes.
Sustainable tools for high-performance components
The focus was on the side pods of the new racing car and thus geometrically demanding structures with aerodynamic and crash-relevant specifications. For the first time, moulds made of conventional corrugated cardboard were used for these CFRP components instead of classic moulding materials. This is a gain in terms of sustainability.
Corrugated cardboard may not seem like an obvious choice of material in this context, but the principle behind it, known as , is simple and pragmatic: the design software cuts the moulding tool vertically into slices the thickness of the corrugated cardboard, thus providing the contours for the two-dimensional corrugated cardboard blanks. Stacking and clamping the elements together already creates a shape that is close to the final contour. Subsequent filling, sanding and sealing creates the surface that, as usual, forms the basis for subsequent lamination.
After use, the top layer can be removed and the cardboard recycled. Alternatively, the mould remains available for any replacement parts throughout the season.
Validation under real conditions
The crucial question was whether the concept would also work outside a laboratory-like experimental manufacturing infrastructure, where climatic conditions can vary and only relatively simple plant technology is available.
The TUC Racing team laminated the components themselves and used them to manufacture the side pods for the 2025 season's racing car. The team was able to successfully implement the process without extensive training. The components proved themselves in competition, and impressively shows the journey from the pure cardboard structure to the coated mould to the painted component on the vehicle.
Transfer to industrial practice
In everyday industrial life, there is a high demand for fast, cost-effective and flexible solutions. Especially in prototype production, small series or frequently changing development stages, metal moulding tools are often a major cost and time factor.
The construction method used here shows great potential for:
- Prototype moulds in early development phases
- Auxiliary moulds for preforming semi-finished fibre products
- Assembly and positioning devices
- Temporary tools for test setups
The decisive advantage lies in the combination of speed, low material costs and high agility. Blanks can be derived quickly and easily from CAD data, and adjustments can be made at short notice. The low weight of the construction method is advantageous for handling and, in particular, for curing the laminates due to the low heat capacity.
TU Chemnitz Racing Team
The collaboration with TUC Racing not only leads to student racing success, but also provides a practical demonstrator for industrial applications.
Promoting young talent, developing potential
In addition to process validation and component manufacturing, recruiting young talent also contributes significantly to overall success. Such a project gives students practical insight into real development processes. From specification, design, procurement, project planning and manufacturing to PR and liability issues, the value creation can be followed in a real-world environment. The collaboration has already resulted in one ongoing student project, and at least one more is in preparation. This strengthens the promotion of young talent and creates prospects for sustainable personnel recruitment.
The collaboration between DLR and TUC Racing clearly demonstrates a win-win situation that will continue with the vehicle for the 2026 season.
Author: Philipp Sämann; Marcel Andres, Robert Prussak