To ensure quality and process reproducibility, the racing team uses the oil-sealed rotary vane vacuum pump GVS 100A, sponsored by Atlas Copco Vacuum. “The robust, compact vacuum pump ensures uninterrupted operation and stable vacuum performance—even under demanding conditions,” says Alexander Braun, sales engineer at Atlas Copco Vacuum in Germany. According to Braun, additional advantages include easy operation, quiet running, and low maintenance requirements.
Vacuum prevents defects in carbon components
“Production begins with cutting and laying up several layers of carbon fiber fabric impregnated with epoxy resin,” explains Marius Hofmann, Chief Technical Officer of the Mainfranken Racing team. These layers are stacked on top of one another, with the fiber orientation varying depending on the direction of the expected loads. “In the next step, the component is either placed in a vacuum chamber or sealed airtight using a special vacuum film,” Hofmann adds.
The vacuum pump generates a stable vacuum that removes air from the chamber or the sealed film enclosure. “This step is critical because the vacuum eliminates trapped air, which would otherwise lead to structural weaknesses such as microcracks in the component and ultimately to defects,” Hofmann explains. At the same time, the negative pressure ensures that the resin penetrates evenly into the fibers while excess resin is expelled. This increases the fiber content, which in turn improves the mechanical properties of the components.
After complete evacuation, the parts are cured for approximately 12 hours to achieve their final strength and dimensional stability. The result is a lightweight and durable carbon component capable of withstanding the demands and material stresses of motorsport.
Clean working environment thanks to integrated oil separation
The Atlas Copco GVS 100A vacuum pump features robust and reliable rotary vane technology specifically designed for these industrial applications. Thanks to its oil-sealed design, it generates a consistent vacuum that is essential for processes such as carbon component manufacturing. Integrated oil separation ensures a clean working environment, while the gas ballast valve facilitates the handling of moist gases. A non-return valve at the inlet protects the system against backflow and increases operational safety. With its compact design, the GVS 100A can be easily integrated and provides a reliable solution for applications where repeatability and quality are critical.
The combination of vacuum technology and student engineering thus demonstrates how essential reliable tools are in the manufacturing of high-performance components. The Atlas Copco vacuum pump not only enables lamination processes but also supports technical education and progress in motorsport.
Mainfranken Racing e.V. is the Formula Student team of the Technical University of Applied Sciences Würzburg-Schweinfurt (THWS) and is organized as a registered student association. Since its founding in 2006, students from various disciplines have developed a new vehicle every year, from the first sketch to the finished race car.
Formula Student provides a learning environment that goes far beyond academic studies. Here, knowledge is applied under real conditions with responsibility and teamwork. Working on the vehicle forces students to approach problems holistically and to truly understand technical relationships.
Each season and each new car challenges the team both technically and organizationally. Students take responsibility for their own areas of work, make decisions, and grow with every challenge. Within the team, different talents and skills come together to form a functioning overall project.
For the aspiring engineers, the competition is not a one-time event but an ongoing process: planning, developing, testing, learning from mistakes, and returning stronger. It is precisely this combination of practical experience, responsibility, and team spirit that makes Formula Student valuable for participants.
Since its founding in 2006, Mainfranken Racing has realized numerous developments and achieved several milestones. The team secured second place in the Newcomers category with its self-developed race car MF1. The prototype marked the team’s entry into the competition and laid the foundation for further technical development.
With the MF7 in 2015, Mainfranken Racing introduced a full aerodynamic package for the first time. Front and rear wings optimized downforce and vehicle stability, improving handling and cornering speeds.
A particularly significant development step came in 2021 with the switch to electric motors in the MF12. This transition opened new possibilities in terms of efficiency, performance, and design concepts and significantly advanced the team both technically and organizationally. The move has since shaped the direction of development.
Composite materials first used in 2022
With the MF14 in 2022, Mainfranken Racing introduced a fully self-developed monocoque made of composite materials for the first time. The integrated design improved weight, stiffness, and ergonomics.
Starting with the MF14 season, the students also developed an autonomous driving system. With the MF15 in 2023, the team presented a fully operational driverless vehicle at events for the first time. The integration of sensors, software, and vehicle technology marked a milestone on the path toward automated race vehicles. Mainfranken Racing is currently working on implementing all-wheel drive for future cars.
These successes demonstrate what the Mainfranken Racing team has achieved in practice. At Formula Student Italy 2025, the team secured first place both in the Overall category and in the Driverless category. Mainfranken Racing also achieved first place in the Overall category at Formula Student France 2024. In the same year, the team reached the podium with third place at Formula Student Czech.