{"id":187939,"date":"2026-09-25T16:35:47","date_gmt":"2026-09-25T14:35:47","guid":{"rendered":"https:\/\/xometry.eu\/?post_type=case&p=187939"},"modified":"2026-09-29T13:18:54","modified_gmt":"2026-09-29T11:18:54","slug":"hydro-team-hydrogen-race-car","status":"publish","type":"case","link":"https:\/\/xometry.eu\/en\/case-studies\/hydro-team-hydrogen-race-car\/","title":{"rendered":"Driven by Hydrogen: How Student Engineers at Hydro Team Accelerate Race Car Development with Xometry"},"content":{"rendered":"\n

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.<\/p>\n\n\n\n

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.<\/p>\n\n\n\n

From Bold Concept to Track-Ready Innovation<\/h2>\n\n\n\n

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.<\/p>\n\n\n\n

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\u2014handling mechanics, aerodynamics, software, and powertrain\u2014working toward their next major milestone: entering full wheel-to-wheel endurance races.<\/p>\n\n\n\n

\"Hydro
Hydro Team KU Leuven with their hydrogen-powered prototype race car<\/figcaption><\/figure>\n\n\n\n

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<\/a> 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.<\/p>\n\n\n\n

The Challenge: Precision Custom Parts with Zero Lead-Time Cushion<\/h2>\n\n\n\n

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.<\/p>\n\n\n\n

Because Hydro Team operates within strict academic calendars and fixed milestone dates\u2014such as first dyno runs and track testing\u2014development 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.<\/p>\n\n\n

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Remi Versele<\/h4>\r\n

Head of Mechanical for Team 3<\/p>\r\n <\/div>\r\n <\/div>\r\n

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Although we try to source off-the-shelf parts, due to the nature of our project, we have to produce a lot of components ourselves… We have no internal CNC capacity, and single pieces are hard to place locally. Some carry full engine torque or maximum suspension loads, so we needed guaranteed materials and precision machining.<\/p>\n <\/div>\r\n <\/div>\r\n <\/section>\r\n\n\n\n

The Solution: On-Demand CNC Machining via Xometry<\/h2>\n\n\n\n

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.<\/p>\n\n\n

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Remi Versele<\/h4>\r\n

Head of Mechanical for Team 3<\/p>\r\n <\/div>\r\n <\/div>\r\n

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For a student team where engineers rotate every academic year, a supplier process that is simple, fast, and repeatable is just as valuable as the high-quality parts themselves.<\/p>\n <\/div>\r\n <\/div>\r\n <\/section>\r\n\n\n\n

To bring their prototype and test bench online, Xometry manufactured four flight-critical component assemblies:<\/p>\n\n\n\n

    \n
  • Dyno Driveshaft (Cardan) Adapter<\/strong>: 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.<\/li>\n\n\n\n
  • Rear Suspension Rockers:<\/strong> CNC milled from high-strength 7075-T6 aluminium to withstand peak pushrod forces while maintaining precise motion ratios.<\/li>\n\n\n\n
  • Steering Shaft Support:<\/strong> CNC milled from structural aluminium to hold rigid bearing alignment between the hub and rack for crisp feedback.<\/li>\n\n\n\n
  • Paddle Shifter Bracket: <\/strong>CNC milled from lightweight aluminium to secure precise paddle positioning through repeated rapid shifts.<\/li>\n<\/ul>\n\n\n
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    \r\n \"3D\r\n
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    3D CAD models of key custom components designed in CATIA 3DEXPERIENCE before sending to Xometry for CNC machining<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

    \r\n \"3D\r\n
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    Technical Spotlight: High Loads and Seamless DFM Feedback<\/h2>\n\n\n\n

    1. Connecting the V6 Engine to the Dyno<\/h3>\n\n\n\n

    Machined from solid steel with strict concentricity, the dyno adapter safely links the Ford V6 flexplate to the dynamometer propshaft without harmonic vibration.<\/p>\n\n\n

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    \r\n \"Hydro\r\n
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    Hydro Team\u2019s V6 engine mounted on the test bench, linked to the dynamometer brake via a custom steel adapter.<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

    \r\n \"Hydro\r\n
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    \r\n \"Close-up\r\n
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    Close-up of the CNC-machined steel cardan adapter mounted on the Ford engine flexplate<\/p>\n <\/div>\r\n <\/div>\r\n \r\n <\/div>\r\n <\/div>\r\n

    \r\n
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    \r\n \"Hydro\r\n <\/div>\r\n
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    \r\n \"Close-up\r\n <\/div>\r\n <\/div>\r\n <\/div>\r\n <\/div>\r\n <\/section>\r\n \n\n\n

    2. High-Strength Rear Suspension Rockers<\/h3>\n\n\n\n

    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.<\/p>\n\n\n\n

    3. Smart Design for Manufacturability (DFM)<\/h3>\n\n\n\n

    During the production of a custom bracket, Xometry\u2019s automated DFM feedback highlighted sharp internal corners in the initial CAD model\u2014a feature impossible to mill cleanly with standard rotating tooling without leaving an internal radius.<\/p>\n\n\n

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    \r\n \"Custom-machined\r\n
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    Custom-machined aluminium paddle shifter bracket installed directly behind the steering wheel<\/p>\n <\/div>\r\n <\/div>\r\n \r\n

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    \r\n <\/div>\r\n <\/div>\r\n \r\n <\/div>\r\n <\/div>\r\n
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    \r\n \"Custom-machined\r\n <\/div>\r\n
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    \r\n

    Remi Versele<\/h4>\r\n

    Head of Mechanical for Team 3<\/p>\r\n <\/div>\r\n <\/div>\r\n

    \r\n

    Xometry provided side-by-side renders comparing our raw CAD with the real-world tool radius (R0.5 mm). It let us confirm within hours that the radius wouldn’t impact part functionality. That proactive loop gave us complete confidence that our models wouldn’t enter production with unmachinable geometry.<\/p>\n <\/div>\r\n <\/div>\r\n <\/section>\r\n\n\n\n

    Accelerating Toward a Zero-Emission Future<\/h2>\n\n\n\n

    With Xometry supplying critical machined components, Hydro Team successfully brought their engine test bench online and continues refining the V0 prototype.<\/p>\n\n\n\n

    As the team prepares to build V1\u2014a heavily modified GT-style race car featuring a 3.5L twin-turbo V6 engine for competition in 2027\u2014they rely on Xometry’s instant pricing, guaranteed tolerances, and transparent lead times to keep every engineering milestone on track.<\/p>\n","protected":false},"author":10,"featured_media":187941,"template":"","meta":{"_acf_changed":true,"inline_featured_image":false},"industryapplication":[1500],"service":[1062],"use-case":[1642,1643],"class_list":["post-187939","case","type-case","status-publish","has-post-thumbnail","hentry","industryapplication-automotive","service-cnc-machining","use-case-prototyping","use-case-r-d"],"acf":[],"yoast_head":"\nHydro Team: Hydrogen Race Car Development with Xometry | Xometry Europe<\/title>\n<meta name=\"description\" content=\"Belgium's Hydro Team used Xometry's on-demand CNC machining to source custom, high-precision metal parts and keep their hydrogen race car project on schedule.\" \/>\n<meta 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