MegaLux
University of Kecskemét
18/5/2025
We dive deep into the challenge of building a solar race car that is both lightweight and structurally reliable for extreme endurance conditions. As core members of the MegaLux team, we contributed to the design phase and took full responsibility for the manufacturing of the carbon fiber monocoque and composite bodywork. Using prepreg technology and honeycomb sandwich structures, we engineered a chassis that was not only stiff and safe but also optimized for minimal weight and aerodynamic efficiency. From master model to final assembly, every step reflected our drive to turn innovative concepts into race-ready reality, resulting in a car that proudly competed at the World Solar Challenge in 2015.
Project Overview
In 2015 our team members played a key role in Hungary’s first-ever entry to the World Solar Challenge in Australia. This ambitious project set out to create an ultra-lightweight, highly efficient solar-powered race car to tackle over 3,000 kilometers across the Australian outback. We were deeply involved in both the design and manufacturing phases, taking full responsibility for producing the complete carbon fiber monocoque chassis using aerospace-grade prepreg in a honeycomb sandwich structure. In addition, we developed and manufactured custom carbon fiber wheels specifically for the race. Beyond the technical challenge, we also took part in the competition as official team members — a once-in-a-lifetime adventure with an incredible group of people.
Process Planning
From the earliest stages we collaborated with the solar car design team to translate the conceptual CAD model into a production-ready composite structure. We engineered the laminate schedule, fiber orientations and sandwich core distribution to optimize load paths and crash safety. The master patterns were CNC-machined from high-density tooling foam, followed by precision mold design to integrate suspension pick-up points, canopy interfaces and internal structural elements. The curing process was planned to maximize resin consolidation and bonding quality using our in-house large-format ovens, enabling autoclave-level results without autoclave processing.
Part Manufacturing
Production began with CNC-machined full-scale master models, followed by the creation of high-accuracy composite molds. The monocoque shells were laminated entirely from prepreg carbon fiber with strategically placed Nomex honeycomb core, vacuum bagged, and oven cured to achieve aerospace-grade mechanical properties. The cured sections were trimmed and bonded together with integrated inserts, forming a complete structural shell ready for final assembly. The result was an exceptionally stiff and lightweight chassis with aerodynamic surfaces directly from the mold, completed on schedule and successfully raced in the 2015 World Solar Challenge.
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