Case Study: Punch Powertrain Solar Team wins 2013 World Solar Challenge with Materialise 3D-printed battery stacking system

3D Printing Powers the 2013 World Solar Challenge Winners to Victory

The Punch Powertrain Solar Team wanted to incorporate 3D‑printed components into their solar car for the World Solar Challenge 2013, focusing on a battery‑stacking system able to hold 432 lithium‑ion cells and integrate more functionality than traditional production methods allowed. They partnered with Materialise to apply 3D printing and design & engineering services to solve the packaging, cooling and weight challenges.

Materialise ran a co‑creation design process that produced a modular open‑frame, honeycomb‑structured stacking system, laser‑sintered in polyamide for lightweight, accurate parts and optimal airflow; the concept reached its final form in just three iterations. The Materialise solution securely housed all 432 cells while reducing weight and improving cooling, helping the team win at the World Solar Challenge 2013 and earn the World Solar Challenge 2013 Innovation Award.

Solar Team

Jens Jespers

Mechanical Systems Engineer