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The solar car “Umicar Infinity”, which was presented this month to the press is a prime example of personalised manufacturing. It is a one-off car of which every single component is custom-built for the Solar Challenge, on the one hand to comply with the regulations and on the other to finish first.

The design regulations for the solar cars competing in the top class of the Panasonic World Solar Challenge have been drastically altered. As from now the drivers will be obliged to enter and exit the solar car independently, whereas in the past the driver was assisted by team members. With a view to commercialising this type of vehicle, ergonomics are also gaining in importance. Safety has also become a major point. For the first time in the history of the event a roll cage must be fitted and the car must be equipped with lights. The solar panel’s size will also be reduced in order for the car to take on the shape of a more conventional vehicle.

In this competition - a 3000 km journey through the Australian desert from Darwin to Adelaide - 45 teams from all over the world are competing for the first place.
With all these specifications, creating a strong concept has become an enormous challenge. So far, the Belgian Solar Team has surely succeeded in materialising that concept and as a result plan to finish in the top 5.

Materialise has built a series of crucial functional components for the suspension (wheel house to keep together 2 components) and the wheels (custom-made sealers) via Fused Deposition Modelling (FDM). An FDM machine works on an "additive" principle by laying down thermoplastic material, which is melted by a heated extrusion nozzle. In a similar manner to stereolithography, the model is built up from layers as the plastic hardens immediately after extrusion from the nozzle.

Since the materials being used are plastics like polycarbonate and ABS, the eventual models are extremely suited for functional tests and for end production. As no moulds are used, there are furthermore almost no restrictions during the design stage.

Materialise is supporting the Belgian Solar Team’s high-tech design and believes they will be one of the first to cross the line in Adelaide.