Radiator Duct Mold
Designed a 3D printed mold to produce a carbon fiber radiator duct for the UWFE cooling system.
Surface Modelling
DFM
Composites
What?
The 2026 vehicle switched from a rear to side-mounted radiator, requiring a custom duct to direct airflow and maximize cooling efficiency
A mold was needed to manufacture the duct in carbon fiber in-house to save costs and avoid outsourcing
The mold had to fit within the printer bed, maintain surface quality, and be easy to demould
How?
Surface modeled the mold in SolidWorks with draft angles, runoff flanges, and trim areas to ensure easy demoulding and a clean surface finish
I split the design into 3 parts to fit onto the printer bed, using press-fit pegs to connect them
The part was 3D printed in PETG, painted with mold release, and laid up with 2 plies of carbon fiber before demoulding
Results?
Produced a geometrically accurate duct that fit the front face of the radiator perfectly
Cut production times by 2+ weeks and reduced costs by over 50% compared to outsourcing
Enabled proper airflow to the side-mounted radiator which supported the cooling system's thermal targets for competition
