SPARK: Onsite Manufacturing & Pit-Stop Challenge
SPARK Lab is a high-performance, four-day intensive workshop hosted by the Universidad Politécnica de Madrid (UPM). Designed to bridge the gap between digital design and real-world implementation, the programme moves validated engineering concepts from the screen to the factory and workshop floor.
During this onsite phase, students will combine hands-on engineering practice with the study of team dynamics in high-pressure environments. Drawing on the principles of Resilience Engineering, participants will explore how teams maintain performance, safety, adaptability, and mutual support when operating under demanding conditions.
Hands-On Technical Modules
– Real Carbon Fiber Lamination: Step out of the digital space and into a sensory, hands-on experience. Teams will execute manual vacuum-bag lamination using real carbon fiber fabrics and epoxy resins to bring their digital designs to physical reality.
– Precision CNC Machining & Turning: Learn the practical setups of operating 4-axis CNC machinery to mill precision aluminum components, bridging the gap between CAM programming and physical tolerances.
– Welding Foundations: Acquire direct, practical exposure to welding techniques, a core skill for structure and chassis manufacturing.
– 3D Printing Validation: Utilise additive manufacturing filament to physically print and test prototype components, checking clearances, dimensions, and manufacturing molds before executing the final production in premium materials.
The Team Dimension: The Pit-Stop Challenge
The technical workshop is anchored by The Pit-Stop Game, a live simulation managed in collaboration with the UPM MotoStudent Petrol association.
Simulating the high-pressure, reactive stress of a professional racing team, groups of 4–5 participants will navigate a landscape of tight time limits, strict budgets, and asymmetric information. You will be forced to solve real-time mechanical failures on a motorcycle platform under time pressure. Throughout the challenge, your team’s stress dynamics and psychological safety will be live-monitored using the Team Thermometer Index, teaching you how to proactively prevent burnout and redistribute team workload on the fly.
Social Purpose & Urban Exhibition
To conclude the experience, the project leaves the laboratory. Teams will showcase their manufactured prototypes in open campus and urban public spaces in Madrid, translating technical engineering metrics into social pride, cultural mediation, and impactful public speaking for non-technical audiences.
Participation
The activity is oriented to candidates who have fully participated in and completed SPARK: Virtual Manufacturing & Design Challenge.
Selection for SPARK Project
The selection Team will value active contribution to the cross-border digital project and the successful validation of the team’s digital design component during Phase 1.
Due to the technical complexity of the machinery, simulations, and workshop dynamics, priority and preference will be given to advanced Bachelor (3rd & 4th year) or Master students enrolled in the following or related fields: Mechanical Engineering Materials Science & Engineering Industrial Design & Innovation Engineering Industrial Technologies Engineering Aerospace / Automotive / Motorsport Engineering.
WHEN
March 2027 – An Specific Day is yet to be defined.
WHERE
Online via TEAMS
APPLICATION DEADLINE
Sign up via Digital Campus until 1 November 2026
This initiative has been funded through the EELISA Joint Call 7, as part of the SPARK – Sustainable Performance Training for Future Engineers: Integrating Wellbeing, Simulation and Collaborative Innovation project.