Case Study: Formula Group T achieves custom, high-performance racecar components with Materialise

Tackling Technical Challenges with 3D Printing from the Outside In

Formula Group T turned to Materialise to push the design freedom of 3D printing on its 2013 EVE racecar after the success of the Areion. Faced with ambitious technical challenges—efficient cooling, brake temperature control, compact and serviceable electronics housings, flexible seals and bespoke mechanical assemblies—the team partnered with the Materialise Design and Engineering team to apply 3D-printing know‑how and appropriate technologies (Laser Sintering and FDM) to the project.

Materialise delivered tailor-made parts—PA12 laser‑sintered air intakes and ducts that improved radiator and brake airflow, a two‑piece splash‑proof circuit board housing for easy access, TPU 92A-1 dust and master-switch covers for dirt/water protection, an ABS FDM open-structure battery stacking system for 360 lithium‑ion cells, and a one‑piece laser‑sintered steering-column gearbox—resulting in better cooling and brake management, reliable electronics packaging, lightweight custom components, and modular battery capacity. By using Materialise’s design-for‑manufacturing expertise and multiple materials/technologies, Formula Group T achieved functional, serviceable, and race-ready solutions that only 3D printing could provide.

Formula Group T

Joris Aerts

Team Leader