Driven by Hydrogen: How Student Engineers at Hydro Team Accelerate Race Car Development with Xometry

By partnering with Xometry for on-demand CNC machining, Hydro Team bypassed procurement bottlenecks, validated their V6 engine test bench on schedule, and established a simple, repeatable manufacturing pipeline that seamlessly hands off from one student cohort to the next.

To bring their zero-emission V6 prototype from CAD screens to the test bench, Hydro Team turned to Xometry as their primary manufacturing partner for custom, flight-critical components.

From Bold Concept to Track-Ready Innovation

Hydro Team was founded to address a critical gap in motorsport and sustainable mobility: while battery-electric setups dominate short-range transport, hydrogen presents the true future for zero-emission endurance racing.

To validate their powertrain, the team developed V0, a rolling prototype featuring the first student-built hydrogen internal combustion engine in Belgium. Today, Team 3 boasts a multidisciplinary group of 13 core engineers—handling mechanics, aerodynamics, software, and powertrain—working toward their next major milestone: entering full wheel-to-wheel endurance races.

Hydro Team operates under a hands-on, full-lifecycle engineering model. Without a separate design office and workshop, the same team member who models a component in CATIA 3DEXPERIENCE is also responsible for placing the order, mounting the physical part, and running validation tests. Every part designed is a custom, one-off solution built specifically to integrate with their bespoke chassis and engine packaging.

The Challenge: Precision Custom Parts with Zero Lead-Time Cushion

In a high-vibration, high-stress automotive ecosystem, generic off-the-shelf catalogue parts rarely fit. Custom adapters, complex suspension linkages, and steering supports must be manufactured from solid, certified metals capable of enduring extreme mechanical loads.

Because Hydro Team operates within strict academic calendars and fixed milestone dates—such as first dyno runs and track testing—development speed is paramount. However, sourcing low-volume or single-piece custom CNC parts through local job shops often presents long lead times and administrative roadblocks.

The Solution: On-Demand CNC Machining via Xometry

Hydro Team partnered with Xometry to source custom, high-precision metal components directly from their 3D CAD models. By leveraging Xometry’s digital platform, the team bypassed the lengthy procurement cycles typical of local machine shops, drastically reducing the time and administrative effort spent hunting for vendors willing to take single-piece orders. Instant pricing and automated DFM feedback filled a critical gap in their internal manufacturing capabilities, providing engineering guidance while keeping project costs predictable under tight student budgets.

To bring their prototype and test bench online, Xometry manufactured four flight-critical component assemblies:

• Dyno Driveshaft (Cardan) Adapter: CNC milled and turned from steel to bolt directly onto the engine flexplate, transferring full V6 torque at high RPMs with strict concentricity to eliminate dyno vibration.
• Rear Suspension Rockers: CNC milled from high-strength 7075-T6 aluminium to withstand peak pushrod forces while maintaining precise motion ratios.
• Steering Shaft Support: CNC milled from structural aluminium to hold rigid bearing alignment between the hub and rack for crisp feedback.
• Paddle Shifter Bracket: CNC milled from lightweight aluminium to secure precise paddle positioning through repeated rapid shifts.

3D CAD models of key custom components designed in CATIA 3DEXPERIENCE before sending to Xometry for CNC machining

Technical Spotlight: High Loads and Seamless DFM Feedback

1. Connecting the V6 Engine to the Dyno

Machined from solid steel with strict concentricity, the dyno adapter safely links the Ford V6 flexplate to the dynamometer propshaft without harmonic vibration.

Hydro Team’s V6 engine mounted on the test bench, linked to the dynamometer brake via a custom steel adapter.

Close-up of the CNC-machined steel cardan adapter mounted on the Ford engine flexplate

2. High-Strength Rear Suspension Rockers

To maintain the exact pivot points and motion ratios calculated in FEA simulations, the rear rockers were CNC-milled from 7075-T6 aluminium, safely handling the peak concentrated loads transmitted through the pushrods.

3. Smart Design for Manufacturability (DFM)

During the production of a custom bracket, Xometry’s automated DFM feedback highlighted sharp internal corners in the initial CAD model—a feature impossible to mill cleanly with standard rotating tooling without leaving an internal radius.

Custom-machined aluminium paddle shifter bracket installed directly behind the steering wheel

Accelerating Toward a Zero-Emission Future

With Xometry supplying critical machined components, Hydro Team successfully brought their engine test bench online and continues refining the V0 prototype.

As the team prepares to build V1—a heavily modified GT-style race car featuring a 3.5L twin-turbo V6 engine for competition in 2027—they rely on Xometry’s instant pricing, guaranteed tolerances, and transparent lead times to keep every engineering milestone on track.