{"id":74013,"date":"2025-09-02T16:26:08","date_gmt":"2025-09-02T08:26:08","guid":{"rendered":"https:\/\/xometry.asia\/?p=74013"},"modified":"2025-09-02T17:09:20","modified_gmt":"2025-09-02T09:09:20","slug":"how-we-set-tunneling-records-and-won-the-not-a-boring-competition-2","status":"publish","type":"post","link":"https:\/\/staging-wp.xometry.asia\/en\/how-we-set-tunneling-records-and-won-the-not-a-boring-competition-2\/","title":{"rendered":"How We Set Tunneling Records and Won the Not-a-Boring Competition"},"content":{"rendered":"\n<p>Hi, we are the TUM Boring team from the Technical University of Munich (Germany). We designed and built a next-generation tunnel boring machine to compete in the international 2025 Not-a-Boring Competition in Texas \u2014 and we won the event, setting a new tunneling distance record. With a clear vision, precise engineering, and bold teamwork, we proved what\u2019s possible when innovation meets smart engineering.<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring.jpg\" alt=\"\" class=\"wp-image-71417\"\/><\/figure>\n\n\n\n<p>At the heart of our success lies a self-developed, next-generation tunnel boring machine \u2014 modular, powerful, and engineered by us, a team of students from the&nbsp;<a href=\"https:\/\/www.tum.de\/\">Technical University of Munich<\/a>. It was built to perform reliably across a wide range of geological conditions. This machine formed the foundation of our record-breaking performance and guided every decision we made along the way.<\/p>\n\n\n\n<p>Building on the experience we gained during&nbsp;<a href=\"https:\/\/xometry.pro\/en\/stories\/tum-tunnel-boring-machine\/\">our participation in the 2023 Not-a-Boring Competition<\/a>, we refined and expanded our ideas to create this record-breaking machine.&nbsp;<\/p>\n\n\n\n<p>The cutting head \u2014 the core component of the record-breaking tunnel boring machine<\/p>\n\n\n\n<p><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2025\/07\/TUM-Boring-The-cutting-head_4.jpg\" alt=\"\"><\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-The-cutting-head_2-scaled-1.jpg\" alt=\"\" class=\"wp-image-71419\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-from-concept-to-record-breaking-machine-the-tum-boring-2024-project\"><strong>From Concept to Record-Breaking Machine: The TUM Boring 2024 Project<\/strong><\/h2>\n\n\n\n<p>The main challenge of the Not-a-Boring Competition, organized by&nbsp;<a href=\"https:\/\/www.boringcompany.com\/\">The Boring Company<\/a>, was clear: bore a 30-meter tunnel as fast as possible. For us at&nbsp;<a href=\"https:\/\/tum-boring.com\/\">TUM Boring<\/a>, this meant combining high performance with maximum versatility. We focused on three key design priorities:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Increased torque at the cutting head<\/li>\n\n\n\n<li>Extended maximum tunnel length<\/li>\n\n\n\n<li>Adaptability to a range of geological scenarios<\/li>\n<\/ul>\n\n\n\n<p>Although the competition rules offered plenty of design freedom, teams had to meet strict safety requirements and work within infrastructure constraints. Based on local soil samples, we expected sticky clay \u2014 and designed a foam-based anti-adhesion system within the cutter head. But once on site, we faced a much harder soil, which unexpectedly slowed progress, underscoring the importance of adaptability.<\/p>\n\n\n\n<p><\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-precision-engineering-from-fluid-mechanics-to-finite-element-analysis\"><strong>Precision Engineering: From Fluid Mechanics to Finite Element Analysis<\/strong><\/h2>\n\n\n\n<p>One of the most complex subsystems was the rotary union in the ground conditioning system. This component had to transfer foam from the non-rotating to the rotating part of the machine \u2014 right into the cutter head \u2014 requiring extremely tight tolerances and high surface finish quality.<\/p>\n\n\n\n<p>Assembly of the new cutting head<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Assembly-of-the-new-cutting-head_3-scaled-1.jpg\" alt=\"\" class=\"wp-image-71420\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Assembly-of-the-new-cutting-head_2-scaled-1.jpg\" alt=\"\" class=\"wp-image-71418\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Assembly-of-the-new-cutting-head_1-scaled-1.jpg\" alt=\"\" class=\"wp-image-71425\"\/><\/figure>\n\n\n\n<p>We used&nbsp;<a href=\"https:\/\/www.autodesk.com\/products\/fusion-360\/overview\">Autodesk Fusion<\/a>&nbsp;to design the entire machine \u2014 leveraging its cloud collaboration features for real-time teamwork. Our engineering workflow included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A structured requirements-definition phase<\/li>\n\n\n\n<li>Multiple concept iterations, evaluated via decision matrices<\/li>\n\n\n\n<li>3D-printed prototypes to physically validate concepts<\/li>\n\n\n\n<li>FEM and CFD simulations to assess mechanical and fluid performance<\/li>\n<\/ul>\n\n\n\n<p><img decoding=\"async\" alt=\"\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2025\/07\/TUM-Boring-Design-process_3-scaled.jpg\"><\/p>\n\n\n\n<p>Working on the tunnel boring machine\u2019s design process in Autodesk Fusion<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Design-process_2-scaled-1.jpg\" alt=\"\" class=\"wp-image-71424\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Design-process_1-scaled-1.jpg\" alt=\"\" class=\"wp-image-71426\"\/><\/figure>\n\n\n\n<p>The entire design, manufacturing, and assembly process was optimized to fit our tight timeline. We designed and ordered the components with the longest delivery times first, though some parts still arrived close to or after our deadlines. Overall, we used as many standardized parts as possible to benefit from their lower cost and shorter delivery times. The custom-made CNC parts were mostly manufactured with external partners due to their large volume and size, while parts with very low complexity and urgent deadlines were produced in-house on our own milling or turning machines.<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2025\/07\/TUM-Boring-Power-Pipe-Manufacturing-1024x683.jpeg\" alt=\"\" class=\"wp-image-117813\"\/><figcaption class=\"wp-element-caption\">Manufacturing of the first tunnel pipe segment<\/figcaption><\/figure>\n\n\n\n<p>Although we didn\u2019t end up needing it before the competition this time, having Xometry as a strategic fallback for unplanned parts or urgent design changes gave us peace of mind. Knowing we had an \u201cace up the sleeve\u201d \u2014 ready to deliver precise CNC parts quickly when time and flexibility became critical \u2014 allowed us to stay focused and confident. Looking ahead, we plan to rely on this rapid manufacturing approach even more in future development cycles.<\/p>\n\n\n\n<p>The assembly process \u2014 similar to our design approach \u2014 followed a \u201cdivide &amp; conquer\u201d strategy: assembling different subsystems separately before integrating them into the overall machine. The same principle guided our testing phase: each subsystem was tested individually, then combined with others, and finally the entire machine with all its subsystems was brought to life.<\/p>\n\n\n\n<p><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2025\/07\/TUM-Boring-Final-Assembly-US-scaled.jpg\" alt=\"\"><\/p>\n\n\n\n<p>Final assembly of the tunnel boring machine in the US<\/p>\n\n\n\n<p><\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Steering-Hydraulics-Assembly-scaled-1.jpg\" alt=\"\" class=\"wp-image-71421\"\/><\/figure>\n\n\n\n<p>Assembly of the steering hydraulics<\/p>\n\n\n\n<p><\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-victory-milestones-and-what-s-next\"><strong>Victory, Milestones, and What\u2019s Next<\/strong><\/h2>\n\n\n\n<p>The most rewarding moment came when we realized we had not only won \u2014 but also set a new tunnel length record. The previous record stood at around 20 meters, and we surpassed it by drilling 22.5 meters. While our machine was designed to go much farther, the unexpectedly hard geology at the competition site threw a spanner in the works \u2014 making the achievement all the more meaningful. It was a powerful milestone that crowned over a year of intense preparation, engineering sprints, and countless hours of teamwork.<\/p>\n\n\n\n<p>And it doesn\u2019t stop there: the next competition has already been announced for 2026. A new TUM Boring team is assembling to push the limits even further \u2014 with a new machine, fresh ideas, and even higher goals.<\/p>\n\n\n\n<p><img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2025\/07\/TUM-Boring-Rollout-event_4-scaled.jpg\" alt=\"\"><\/p>\n\n\n\n<p>Scenes from the TUM Boring Rollout Event 2025, where the team presented their tunnel boring machine ahead of the Not-a-Boring Competition<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Rollout-event_6-scaled-1.jpg\" alt=\"\" class=\"wp-image-71423\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Rollout-event_2-scaled-1.jpg\" alt=\"\" class=\"wp-image-71428\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Rollout-event_1-scaled-1.jpg\" alt=\"\" class=\"wp-image-71427\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-Rollout-event_3-scaled-1.jpg\" alt=\"\" class=\"wp-image-71422\"\/><\/figure>\n\n\n\n<p><\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-engineering-education-beyond-the-classroom\"><strong>Engineering Education Beyond the Classroom<\/strong><\/h2>\n\n\n\n<p>The lessons we learned go far beyond mechanics. We reflect on three key takeaways: people are the ultimate success factor \u2014 both the team and its supporters; divide and conquer: breaking the project into subsystems prevents chaos and enables parallel innovation; and industry partners like Xometry are strategic enablers, not just suppliers.<\/p>\n\n\n\n<p><\/p>\n\n\n\n<p>TUM Boring team photos from fieldwork and rollout activities for the Not-a-Boring Competition<\/p>\n\n\n\n<figure class=\"wp-block-image\"><img loading=\"lazy\" decoding=\"async\" width=\"2560\" height=\"2048\" src=\"https:\/\/xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1.png\" alt=\"\" class=\"wp-image-74014\" srcset=\"https:\/\/staging-wp.xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1.png 2560w, https:\/\/staging-wp.xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1-480x384.png 480w, https:\/\/staging-wp.xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1-1440x1152.png 1440w, https:\/\/staging-wp.xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1-768x614.png 768w, https:\/\/staging-wp.xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1-1536x1229.png 1536w, https:\/\/staging-wp.xometry.asia\/wp-content\/uploads\/2025\/09\/1756801558-TUM-Boring-team_1-scaled-1-2048x1638.png 2048w\" sizes=\"auto, (max-width: 2560px) 100vw, 2560px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-team_3-scaled-1.jpg\" alt=\"\" class=\"wp-image-71430\"\/><\/figure>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/xometry.au\/wp-content\/uploads\/2025\/08\/TUM-Boring-team_4-scaled-1.jpg\" alt=\"\" class=\"wp-image-71429\"\/><\/figure>\n\n\n\n<p>Great ideas attract great allies \u2014 clear communication of technical innovation inspires support. A tunnel boring machine is never a solo effort; it\u2019s the result of engineering excellence, team spirit, and trusted partners who show up when it counts.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p><strong>From first sketches to final results, each project leaves us with lessons and stories to tell. What has your most challenging project taught you?<\/strong>&nbsp;Share it with us in the comments.<\/p>\n\n\n\n<p><a href=\"https:\/\/xometry.pro\/en\/stories\/tum-boring-record-win-2025\/#\"><\/a><\/p>\n\n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>The TUM Boring team, leveraging innovative design and support from Xometry, set a new tunneling record and won the Not-a-Boring Competition.<\/p>\n","protected":false},"author":37,"featured_media":73816,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[36,735],"tags":[],"class_list":["post-74013","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-customer-stories","category-innovation-stories-en"],"acf":[],"publishpress_future_action":{"enabled":false,"date":"2026-09-13 20:09:24","action":"change-status","newStatus":"draft","terms":[],"taxonomy":"category","extraData":[]},"publishpress_future_workflow_manual_trigger":{"enabledWorkflows":[]},"_links":{"self":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/posts\/74013","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/users\/37"}],"replies":[{"embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/comments?post=74013"}],"version-history":[{"count":0,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/posts\/74013\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/media\/73816"}],"wp:attachment":[{"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/media?parent=74013"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/categories?post=74013"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/staging-wp.xometry.asia\/en\/wp-json\/wp\/v2\/tags?post=74013"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}