3D-printing a new manifold injection system for optimal fuel efficiency.

At Albert‑Einstein‑Straße 2 in Rostock, a dedicated group of students from the University of Rostock has come together under the banner of Hanseatic Efficiency. This Shell Eco‑Marathon team is united by a shared ambition. Students from diverse engineering disciplines design, build, and optimize ultra‑efficient prototype cars aimed at maximal range on minimal fuel. At international events such as the Shell Eco‑Marathon, they apply lean design principles and advanced materials science to push the boundaries of sustainable mobility. Their record in 2024? An impressive 1005 km per liter of petrol—a testament to ingenuity in lightweight construction, meticulous aerodynamics, and strategic teamwork. In this years update they incorperated resin 3D-printing technology in an effort to beat this record.

Image from Hanseatic Efficiency: new manifold injection system 3D-printed with Liqcreate Rigid Pro resin installed.

Image from Hanseatic Efficiency: new manifold injection system 3D-printed with Liqcreate Rigid Pro resin.

In preparation for the 2025 Shell Eco-marathon, the Hanseatic Efficiency team has rolled out a series of upgrades aimed at boosting their vehicle’s fuel efficiency—chief among them, a redesigned engine component. One of the innovations lies in the development of a new manifold injection system, responsible for forming the air–fuel mixture before it enters the combustion chamber. Given the component’s exposure to elevated temperatures and direct contact with fuel, material selection was critical. After careful evaluation, the team opted to manufacture the part using Liqcreate Rigid Pro, a high-performance resin known for its thermal and chemical resistance. The material will now face real-world testing as part of the team’s 2025 vehicle. This upgrade marks a strategic move by the team to push the limits of energy efficiency in one of Europe’s most competitive student engineering contests.

In 2024, Hanseatic Efficiency reached a major milestone by achieving a fuel efficiency of 1,005 kilometers per liter of petrol during the Shell Eco-marathon in Nogaro, France. This placed them on 11th position on the leaderboard. This result was the product of extensive testing, iterative design, and precise engineering. The team focused on minimizing energy loss through aerodynamic refinement, lightweight construction, and an efficiently tuned combustion system. The record not only demonstrated their technical capabilities but also highlighted their ability to work together under real-world conditions, positioning them among the top-performing student teams in Europe. This year they changed designs and upgraded the manifold injection system of their engine.

Image from Hanseatic Efficiency: new manifold injection system 3D-printed with Liqcreate Rigid Pro resin.

Image by Hanseatic Efficiency: Celebrating the new personal record at Shell Eco-marathon 2025.

After months of preparation, the Hanseatic Efficiency team has returned from the 2025 Shell Eco-Marathon, held in mid-June, with record-breaking results and a major leap in standings. The student team from the University of Rostock achieved an astounding 1,269.5 kilometers per liter, setting a new team record and reaching an equivalent fuel consumption of just 0.0078 liters per 100 kilometers. The breakthrough performance propelled the team from 11th to 4th place in their category—an achievement that reflects both technical ingenuity and consistent improvement.

A key contributor to this success was the use of a newly developed 3D-printed intake manifold, designed to increase internal volume and allow for fresh air intake through an external hose. This innovation significantly improved cold-start performance, one of the team’s main objectives for the season. The component was manufactured using Liqcreate Rigid Pro, a rigid, high-temperature-resistant resin, and demonstrated impressive durability under extreme conditions—including exposure to petrol fumes, elevated engine heat, and occasional backfires.

The team is now back in Rostock, analyzing data and planning future improvements, with more resin 3D-printed parts in their vehicle next year!