Motorsport is as much about engineering brilliance as it is about speed. Every component must perform perfectly under pressure, and few challenges test that more than Formula Student. The competition sees university teams design, build, and race single-seater cars at Silverstone, putting future engineers to the ultimate test.
When the University of Leicester Racing Team set out to build their 2025 Formula Student car, they needed a bespoke exhaust system capable of meeting the competition’s demanding performance and packaging requirements. In order to help take their designs from the drawing board to the track, they reached out to Europe’s leading manufacturer of aftermarket exhausts – Klarius Products.
A partnership built on experience
The Leicester team were introduced to Klarius through Staffordshire University, who have worked with the company on several successful Formula Student builds. With a reputation for precision engineering and rapid prototyping, Klarius was the natural partner to deliver a one-off exhaust solution worthy of the racetrack.
The project was led by Jayson Prince, Research and Development Engineer at Klarius and a former Formula Student competitor himself. His insight into both the academic and industrial sides of motorsport engineering proved invaluable.
“I remember the long nights working on my own Formula Student car,” says Jayson. “So it’s a great feeling to help a new generation of engineers achieve their design goals. Having been in their shoes, I know how much this means to them.”
Turning design into reality
Every Formula Student car requires a fully bespoke exhaust to balance power, weight, and regulatory demands. Working from the team’s CAD model, Klarius’ R&D team conducted a comprehensive design and manufacturing review, ensuring that the proposed layout could be fabricated to the highest standards.
Using its extensive in-house capabilities, the company manufactured the custom manifold to exact specification. High-grade stainless-steel tubing was precision-cut, shaped, and TIG-welded by skilled engineers, while Klarius’ sister company KMT laser-cut a bespoke jig to guarantee perfect alignment during assembly.
The result was a complete, race-ready exhaust system built with the same attention to detail and quality control found in every Klarius product.
“The finished product hit all the right notes,” says Jayson. “We were able to take the University of Leicester team’s concept, apply our manufacturing expertise, and produce a component that would deliver top performance on the track.”
Driving engineering excellence
This collaboration gave the student team a close-up look at how professional manufacturers develop high-performance components from CAD model to finished product. For Klarius, it was another opportunity to demonstrate both its versatility and technical strength.
“At Klarius, prototyping and development are at the heart of what we do,” adds Jayson. “Whether it’s a production exhaust for a daily driver or a custom manifold for a race car, the same dedication to performance and precision applies.”
Inspiring the next generation
For the Klarius team, supporting projects like this is about more than sponsorship. It’s about investing in the next generation of automotive engineers and keeping the spirit of innovation alive.
“A lot of us in the R&D team are massive petrolheads,” says Jayson. “We love cars, we love engineering, and Formula Student is where that passion starts for many people. It’s fun to be part of something that inspires the next wave of designers and engineers.”