With a top speed reaching 130 km/h, this race car is exceptionally cool!
As shown in the image above, this fully electric race car is designed and manufactured by the University of Pisa Formula Racing Team (E-Team Squadra Corse) from Italy. The entire car weighs 240 kg, and its top speed can reach 130 km/h.
On the racing track where the limit of speed is pursued, “weight reduction” is the most direct and effective method. However, race cars face high structural loads when traveling at high speeds. Then, how to balance lightweighting, structural safety, and manufacturing costs?
In addition to conducting critical design optimization, making bold innovations, and introducing new technologies, the team has also conducted in-depth explorations on lightweighting and comprehensive performance optimization at the material level. First, carbon fiber and metal materials are retained in core stress-bearing parts; second, additive manufacturing (3D printing) is applied on a large scale in component development.
Team members introduced: “By using 3D printing to manufacture brackets, fasteners, battery module components, aerodynamic tooling, and protective assemblies, we have significantly reduced manufacturing time, production costs, and component weight.”
*Note: Before being installed on the race car, critical components underwent internal verification and repeated structural strength testing to ensure their mechanical properties meet the application requirements.
Among them, eSUN’s series of 3D printing materials have played a crucial role in different parts of the race car.
High-Voltage Battery System: Dual Requirements of Flame Retardant Specifications and Impact Resistance
When the race car is running at a high speed of 130 km/h, the battery will not only generate high temperatures but also needs to withstand bumps and vibrations. Therefore, the team selected eSUN UL94-V0 flame-retardant ABS material for the high-voltage battery housing and internal supports.
The high-voltage battery module material customized based on ABS flame-retardant materials meets the flame retardant specifications required by the event organizers, and it performs excellently in practical applications. Our structural test results show that these modules can almost withstand pressures up to twice the designed load.
——E-Team Squadra Corse —— E-Team Squadra Corse
Aerodynamic Kit Master Mold Manufacturing: Dimensional Stability of Large-Sized Components
The aerodynamic shape of a race car has a decisive impact on lap times. When manufacturing carbon fiber aerodynamic components, the team needs to first create large-sized fiberglass laminated master molds. Since these molds are used for shape definition and do not bear the mechanical loads of the vehicle, dimensional stability and molding precision have become the primary indicators. Based on the above demands, the team selected eSUN PLA+ material.
The greatest advantage of PLA+ lies in its good printability and dimensional stability. The printing failure rate of this material is extremely low, and warping deformation almost never occurs. This is particularly important for large components, as many models need to be spliced together from multiple printed segments. PLA+ can ensure that the surface transition after splicing is smooth without obvious gaps, thereby providing a high-quality foundation for subsequent mold making.
The high efficiency and high reliability of PLA+ enable us to quickly complete the manufacturing of large-sized components.
——E-Team Squadra Corse —— E-Team Squadra Corse
High-Strength Functional Components: High-Temperature and Wear-Resistant Engineering Plastics
For some high-strength functional parts that relied on aluminum alloy machining in the past, the team attempted to introduce a lighter engineering material — eSUN PA-CF.
PA-CF possesses excellent high-temperature resistance. The components printed by the team using this material can smoothly withstand the high-temperature and high-pressure cycles in the autoclave during the composite material curing process. In addition, PA-CF also features outstanding toughness and wear resistance. Relevant printed parts can be applied to high-wear areas such as the skid blocks at the bottom of the front wing, providing reliable physical protection when the race car is driving close to the ground.
The excellent performance of PA-CF provides a strong guarantee for the final performance optimization of the race car. By using this material, we have significantly reduced manufacturing costs and production cycles, further optimizing the overall vehicle weight and performance. In terms of printing, it is also relatively easy to get started with, and the surface texture of the parts is outstanding.
——E-Team Squadra Corse —— E-Team Squadra Corse
Regarding the materials sponsored by eSUN this time, the team gave a high overall evaluation: “Whether in rapid prototyping or the manufacturing of functional racing components, eSUN’s 3D printing materials have demonstrated excellent quality and reliability.
Through the uniform and stable filament supply from eSUN, the consistency and repeatability of the manufacturing process have been significantly improved, enhancing work efficiency. This also gives us more confidence to further expand the application scope of additive manufacturing technology and efficiently complete the ultimate optimization of the race car.”
The Sponsorship Program is Ongoing!
Materials empower intelligent manufacturing. eSUN is also very pleased to join global university innovation teams to continuously explore more possibilities of 3D printing materials in cutting-edge engineering fields such as race cars, robots, and drones.
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